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Chapter 1. General Information

1. Reference Air Inlet Flowmeter HI Gauge SM iii o J i PR Valve Reference Air Supply Calibration Gas Supply Figure 7 A Typical FGA 311 System 16 FGA 311 User s Manual Chapter 3 Operation and Programming Chapter3 Operation and Programming 3 1 Introduction Because the FGA 311 In Situ Flue Gas Oxygen Transmitter is a monitoring device operation of the installed analyzer is simple Once it has been properly installed and set up it will simply begin taking readings However the analyzer should be allowed to warm up for at least one hour three hours if possible prior to use See Installation on page 7 if all of the required installation requirements have not yet been completed Calibration of the unit should be checked once or twice a week for the first month of operation and once every 2 3 months thereafter See Calibration on page 37 for the correct procedures WARNING To ensure safe operation of the FGA 311 it must be installed and operated as described in this manual In addition be sure to foll
2. Zirconium Oxide Ceramic with Lattice Imperfections From Outside From Inside Electrode Electrode When O concentration in sample gas falls cell voltage rises with increased O migration rate Figure 3 Oxygen Migration Through the Sensor 4 FGA 311 User s Manual Chapter 1 General Information 14 The Heater Control Circuit The oxygen sensor temperature in the FGA 311 is maintained by a heater which is part of a complex temperature control loop This circuit constantly monitors the oxygen sensor temperature compares it to the set point temperature 700 C and turns the heater ON or OFF accordingly The specific type of control circuit used is called a Proportional Integral Derivative PID loop because of the three adjustable parameters involved e Proportional Band Because the system cannot respond instantaneously to temperature changes the actual temperature of the oxygen sensor oscillates about the set point In general increasing the proportional band reduces the magnitude of these temperature oscillations e Integral Action A consequence of increasing the proportional band is the introduction of an offset between the set point and the control point The integral portion of the control loop acts to move th
3. Flame Arrestors Figure 1 The FGA 311 Enclosures 2 FGA 311 User s Manual Chapter 1 General Information 12 Principles of Operation In an ideal combustion process a precise ratio of air to fuel is burned efficiently to yield only heat water vapor and carbon dioxide However because of burner aging imperfect air to fuel mixtures variable firing rates and or inaccurate ignition timing this situation rarely happens A sure sign of a less than ideal combustion process is the presence of excess oxygen in the flue gases The level of this excess oxygen is easily monitored with the FGA 311 In Situ Flue Gas Oxygen Transmitter and the information can then be used to make the necessary adjustments to improve the efficiency of the combustion process The following two major components are included in the FGA 311 analyzer e azirconium oxide oxygen sensor e aloop controlled heater circuit These components are described in the sections that follow 13 The Oxygen Sensor The inside and outside of the zirconium oxide oxygen sensor are coated with a porous platinum catalyst forming two electrodes Flue gases flow past the outside of the sensor while atmospheric air circulates freely on the inside of the sensor The atmospheric air is used as the reference gas for the oxygen measurements See the oxygen sensor sub assembly shown in Figure 2 At the normal
4. TB2 4 N LI 703 1216 MODE TX FAULT yoo E8 2 5 1025 E9 A Z S2 ADJ e Figure 8 Circuit Board Switches and LEDs 20 FGA 311 User s Manual Chapter 3 Operation and Programming 3 8 1 Description of Switches and LEDs The following switches and lights will be found on the printed circuit board of the FGA 311 e MODE Switch S1 a 10 position rotary switch that is used to select the desired menu option e ADJ Switch S2 a rotary encoder switch used to adjust the value of numeric menu options selected with Switch S1 e CAL Switch S3 a push button switch used to enter and exit programming mode and to confirm the programming option set with Switch S1 e DS1 DS3 three green LEDs that are used to indicate the selected oxygen range setting e DS4 ared LED that is used as a fault indicator e DS5 a yellow LED that indicates the heater duty cycle The specific menu options that may be selected with the 10 position rotary MODE Switch S1 are listed in Table 1 Table 1 MODE Switch S1 Positions Switch Position Menu Option 1 AIR TRIM_O2 4mA TRIM O2 20mA Not Used Not Used Note Only five of the nine positions on Switch S1 1 5 are currently active Positions 6 9 are not used at this time Navigating through the FGA 311 built in User Program software is easily accomplished by completing the detailed steps in the following section
5. not accessible manual switches FGA 311 User s Manual EXTRA 4mA_O2 xxx ADJUST 20mA_O2 xxx ADJUST ER2 SET ER2 xx x MA ER3 OFF ER3 SET ER3 xx x MA ER4 OFF ER4 SET ERA xx x MA SET xxx Degrees C P xxx Degrees C xxx Seconds using O xxx Degrees C DEFAULT FREEZE UNFREEZE RESP RESP xx Seconds OFST 1 2345 DUTY CYCLE The user will respond Yes or No to some options OFFSET Figure 10 FGA 311 Menu Map 35 Chapter 4 Calibration Chapter4 Calibration 4 1 Introduction The calibration of the FGA 311 In Situ Flue Gas Oxygen Transmitter should be checked once or twice a week during the first month of operation and every 2 3 months thereafter Changes in calibration may result from aging of the oxygen sensor and within limits temperature calibration adjustments can compensate for such variations WARNING To ensure safe operation of the FGA 311 it must be installed and operated as described in this manual In addition be sure to follow all applicable local safety codes and regulations fo
6. NOTE These connections are made Ground wire goes to at the factory earth gnd connection 703 1216 RS232 Analog Output TB2 Terminal Block Thermocouple and Sensor J2 Terminal Block Description Return i Description Receive RS232 Thermocouple Send Thermocouple 4 20 mA Out Zirconium Oxide Oxygen Sensor 4 20 mA Out Zirconium Oxide Oxygen Sensor Future Use CJC OTES Future Use CJC 1 PC Board may be oriented differently NOTE These connections are made depending on how the unit is installed at the factory 2 J1 is reserved for future use Shown with sensor heater assembly and cable removed for clarity Figure 6 Connections to the FGA 311 PC Board FGA 311 User s Manual 13 Chapter 2 Installation 2 1 Wiring the Control Signals Use the remaining 3 4 NPT port on the FGA 311 enclosure for connecting the control cable gland or conduit For cable runs of less than 5 m 16 4 ft standard twisted pair cable may used for these connections However shielded cable should be used for longer cable lengths or for CE Mark compliance IMPORTANT This symbol indicates Caution risk of electric shock LN The control signal connections are made to the printed circuit board on terminal block TB2 as shown in Figure 6 on page 13 To make the necessary connections complete the following st
7. FGA 311 User s Manual 21 Chapter 3 Operation and Programming 3 8 2 Manual Programming Instructions Use the following instructions to program the FGA 311 with the printed circuit board switches Set Switch S1 1 Push CAL Switch S3 and hold for 5 seconds to set the AIR calibration A green LED will blink until the calibration is complete Press Switch S3 and hold for 5 seconds to EXIT programming mode IMPORTANT A ways complete the AIR calibration before attempting the GAS calibration Also The red fault LED may glow temporarily during the GAS calibration procedure Set Switch S1 2 Push CAL Switch S3 and hold for 5 seconds to set the GAS calibration Adjust the value with ADJ Switch S2 until a green LED starts blinking Press Switch S3 and hold for 5 seconds to EXIT programming mode Note Refer to Calibration on page 37 for a detailed description of the calibration procedures Set Switch S1 3 Push CAL Switch S3 and hold for 5 seconds to access the RANGE option The current O range LED will blink Adjust the value with ADJ Switch S2 until the green LEDs start blinking Press Switch S3 and hold for 5 seconds to EXIT programming mode Set Switch S1 4 Push CAL Switch S3 and hold for 5 seconds to access the TRIM_O2 4mA option Adjust the value with ADJ Switch S2 until the output signal reads 4 mA Press Switch S3 and hold for 5 seconds to EXIT programming mode Note For the TRIM O2 function always adjust the 4 mA s
8. 705 1028 04 Sensor Assembly Normal Temperature 230 VAC 705 1028 05 Sensor Assembly High Temperature 230 VAC 705 957 02 Filter Tip Normal Temperature 705 957 03 Filter Tip High Temperature 707 247 098F Instrument Program EPROM Flowmeter Reference Gas 200 psig 20 to 400 cc min 098C 64 Flowmeter Calibration Gas 200 psig 0 5 to 5 0 SCFH FGA 311 User s Manual Chapter 7 Specifications Chapter 7 Specifications 7 1 Performance Accuracy 3 of reading or 0 1 O Measurement Resolution Analog Output 0 01 mA RS232 Output 0 01 O Response Time Less than 5 seconds for a 63 step change Measurement Range Fully field selectable via RS232 interface or on board switches 0 5 O 0 10 O 0 25 O FGA 311 User s Manual 65 Chapter 7 Specifications 7 2 Operational Process Temperature Standard Temperature 150 to 650 C 300 to 1200 F High Temperature 150 to 1050 C 300 to 1920 F Ambient Temperature Electronics 20 to 70 C 4 to 160 F Calibration Methods RS232 interface manual via PC Digipot adjustment semi automatic via push button Recommended Calibration Gas Mixture Zero Gas 5 0 Op balance N depends on application and range Span Gas 20 93 O balance N5 Flow Rate 2000 cc min 4 SCFH Reference Air Composition instrument air 20 93 O regulated to 3 psi 20 kPa Flow Rate 20 to 50 cc min 0 04 to
9. ER2 SET To set ER2 press SPACE to select ER2 SET and press ENTER SET ER2 ER2 xx x mA Enter the desired value and press ENTER Press BACKSPACE to back up one menu level ER3 the Open Thermocouple error message ER1 ER2 ER3 ER4 Press SPACE to select ER3 and then press ENTER Proceed to either the Disable ER3 or Set ER3 prompt ER3 OFF ER3 SET To disable ER3 make sure ER3 OFF is highlighted and then press ENTER Press Disable ER3 BACKSPACE to back up one menu level ER3 OFF ER3 SET To set ER3 press SPACE to select ER3 SET and press ENTER SET ER3 ER3 xx x mA Enter the desired value and press ENTER Press BACKSPACE to back up one menu level FGA 311 User s Manual 29 Chapter 3 Operation and Programming 394b Error Handling Set Up cont ER4 the Heater Failure error message ER1 ER2 ER3 ER4 Press SPACE to select ER4 and then press ENTER Proceed to either the Disable ER4 or Set ER4 prompt ER4 OFF ER4 SET To disable ER4 make sure ER4 OFF is highlighted and then press ENTER Press Disable ER4 ER4 OFF ER4 SET SET ER4 ER4 xx x mA 30 BACKSPACE to back up one menu level To set ER4 press SPACE to select ER4_SET and press ENTER Enter the desired value and press ENTER Press BACKSPACE to back up one menu level FGA 311 User s Manual Chapter 3 Operat
10. dangerously hot surfaces and risk of electric shock respectively A AN 2 Place a large screwdriver or similar tool across the two slots located on the cover Using the screwdriver as a lever begin to rotate the cover in a counter clockwise direction After the cover has been loosened continue to unthread it by hand and pull the cover away from the enclosure Complete whatever maintenance is required within the enclosure as instructed later in this chapter 4 Make sure that the o ring is still in place on the cover and thread the cover back into the enclosure Using the large screwdriver across the slots tighten the cover securely 5 Lock the cover in place by tightening the set screw located near one of the slots The FGA 311 may now be placed back into service 6 4 Fuse Replacement To replace the fuse in the FGA 311 refer to Figure 16 on page 58 and complete the following steps 1 Disconnect the main power from the analyzer WARNING Disconnect the main power from the unit and allow at least two hours for the system to cool down before proceeding with the following steps 2 Remove the cover from the enclosure as described above 3 Pull the soft plastic protective cover off the fuse holder 4 Pull the fuse out of its holder and replace it with a new fuse See Specifications on page 65 for the correct replacement fuse ratings 5 Reinstall the protective plastic cover over the fuse holder 6 Reinstall the
11. 0 11 SCFH 66 FGA 311 User s Manual Chapter 7 Specifications 7 3 Functional Output 4 20 mA Analog Output isolated 600 ohm maximum Digital Output RS232 communications Input Power 115 VAC 230 VAC Power Consumption 75 W Process Connection Standard 1 1 2 NPTM Optional 2 and larger flanges FGA 311 User s Manual 67 Chapter 7 Specifications 74 Physical Materials of Construction Enclosure Epoxy coated aluminum Probe Standard Temperature 316 SS process wetted or welded parts Probe High Temperature Inconel alloy process wetted or welded parts Probe Lengths 19 1m 15m 2m Probe Weight 19 Probe 6 8 kg 15 Ib Probe Mounting Orientation vertical or horizontal 1 1 2 NPT Type flange available in most common sizes Hazardous Area Certifications Weatherproof NEMA 4X IP66 Explosion proof Flameproof C US Certification No 1622936 Class I Div 1 Groups B C D T6 electronic housing T4 sensor probe ISSeP02ATEX028 X Electronics II 2 GD EEx d IIB T6 ISSeP02ATEX028 X Process IL 2 GD d IIB T2 European Compliance Complies with EMC Directive 2004 108 EC and LVD Directive 2006 95 EC Installation Category II Pollution Degree 2 and PED 97 23 EC for DN 25 68 FGA 311 User s Manual Appendix A The Nernst Equation AppendixA The Nernst Equation A 1 Introduction The FGA 311 In Situ Flue Gas Oxygen Transmitter uses the Nernst Equation
12. 215 RS232 Output Use shielded cable such as GE P N 704 668 12 or equivalent to interconnect the FGA 311 enclosure with any external I O devices 2 Terminate the shield to the recommended cable gland GE P N 419 215 Wires enclosed in a properly grounded metal conduit do not require additional shielding WARNING Cable entries of an approved flameproof design are required These must be installed according to the manufacturer s instructions The choice of cable entry device may limit the overall installation category achieved WARNING Itis the responsibility of the user to ensure that all cable entry devices and covers are properly installed and secure prior to applying power to the XMTC C 1 2 LVD Directive For compliance with the LVD directive the FGA 311 requires an external power disconnect device such as a switch or circuit breaker The disconnect device must be marked as such clearly visible directly accessible and located within 1 8 m 6 ft of the FGA 311 It must be clearly marked as being the disconnect device for the analyzer Note Ifyou follow the instructions in this section your unit will comply with the 2006 95 EC LVD Directive with the following exception the 230 VAC unit passes with a test voltage of 1 800 VAC refer to Table D 10 of Annex D in EN61010 FGA 311 User s Manual 79 80 no content intended for this page FGA 311 User s Manual Appendix D Data Records AppendixD Data
13. 7 4 Oxygen Reading Lower Than Expected The zirconium oxide oxygen sensor will respond to combustibles such as CO H or other hydrocarbons in the sample gases by generating several millivolts of additional voltage output Although the FGA 311 will accurately process this information the resulting oxygen reading will be lower than expected Some possible sources of such contamination are e oil or grease in the plumbing system pipe thread compound on the fittings oil or grease on the oxygen sensor due to handling the sensor with bare hands excess fuel in the burner Resolve the problem be finding and eliminating the source of the contaminating combustibles 5 7 5 Oxygen Reading Higher Than Expected The likely cause of an oxygen reading that is higher than expected is a gas leak that permits the reference air to become contaminated with the process flue gases This contamination will lower the millivolt output of the zirconium oxide oxygen sensor and the 4 20 mA output signal will indicate an oxygen percentage that is higher than expected Although the FGA 311 will accurately process this information the result will not reflect the actual oxygen content of the flue gases To correct the problem find and correct any plumbing leaks that could cause the above contamination to occur 54 FGA 311 User s Manual Chapter 6 Service and Maintenance Chapter 6 Service and Maintenance 6 1 Introduction Although the FGA 311 has b
14. MENUnz4 aasahan an Pamana bh wL LANA quee barbie a Red IGAN A RAE TNA E dU KGG NAE EE di GR adatti 26 3 9 3a Trim Oxygen Output riu AAPPEAR pad d Rabe 26 SOA EXTRA Men M Y 27 3 9 4a Selecting Terminal Type sisse Hmmm emn 27 394b Error Handling SOW naaawa BAG Sob esa Er Rd EU EGRE UU EB SER NG Pau a Re Sa Eua cad 28 3 9 4c Set Up Heater CODIOL coe Lisaexsidutet haaa DID TSK G ENNA PLEMA PG n Lr PAPIAM PPddedd 31 FGA 311 User s Manual iii Contents 4 1 4 2 4 3 44 45 3 940 Freeze a REadiGisivcctivecceideviitevarsnetoutiiceck E E E E Gre YER RR E EOD EROR na 33 3 9 4e Setting the Response Time 0 cee cece eee III nnn 33 Chapter 4 Calibration Te AA 37 Recommended Calibration GAS aanak ka ANING RR RR aRRRRYERREERRRuR RR ERPRERGu Raw EUER Ra ara 37 Measuring the Calibration RESPONSE cias ete ccc c co ERR RE Ed pIEe ERE RG PARN RE DERE RE RE EE a 38 The Calibration Gas SySEeITI usas vcr ee nnn ebbe ANA AA E Ras EEA Pep GG 38 Calibrating the Oxygen BENSON asas pera oec irte diee erase ABER EYE NIN NAAN siint Sada DRE or 40 4 5 1 Calibrating with the Manual Switches ccc cece cece ect eee mmm 40 452 Calibrating with a PC Connection uiisisossssesakebbkr rr prr RI RERRE nA ERU RR RE RE eria 41 RESUME OPETALON RECTUS 42 4 6 Chapter 5 Troubleshooting 5 1 5 2 93 54 9 9 5 6 Bud a siiis nnne EID EET TL QUID UEL ITI 43 Troubleshooting Guide AA AA APA AA T 44 Rr seo ecd
15. NER EET TEE EO APP 45 Sensor Heater WING PA AA YR E ER ERR RR 46 Temperature PIODIOMS sntccnd iius aen plaines aea KARD ox lh aan need eed de a a Mk AA ANAY 46 Bia Bh Error COO uisueossusrd auda Paa ex dott ieee E ANAKAN Cotta NAA Na aod 47 sowas oido iN AA AA APA AA AP PEO 48 95S ERA ENOrC OdG AA AAP 49 Output PO ICING AA AA TT 50 50 1 Al Outputs Inge VB uuceos aeecc x Seer renane e ook eb rete bebe dapes E a o 50 552 NG N0232 D LDUE ooo Cio t pectet o ete xt Tura de qoo laii URS ex Apud dine EREE 51 Oxygen Reading Problems AAP 51 ENIM zi Error Codes APA AA PAR AA 52 5 7 2 Oxygen Percentage Always Reads 20 93 auuu 53 5 7 3 Oxygen Percentage Unchanged for more than 15 Minutes 53 5 7 4 Oxygen Reading Lower Than Expected iiiicie esee re Ree eren n e NG KKK 54 5 7 5 Oxygen Reading Higher Than EXDeCUBd 2 abaka beer btrpEEER RE pEpEbRE OR KE PP brixb o Rerr i eda 54 FGA 311 User s Manual Contents Chapter 6 Service and Maintenance Ol IMroJUCtHON AA PAA 55 Dh Probe Tip ReplacEmMeEnt seisce beeteteanri nns ieretna k n hena EA ai a EE aE RE EEEE aa EE TUE 55 6 3 Cover Removal and Reinstallation 0c cece cece emen 56 6 4 Fuse Replacement lt ccisccaccctasgdescgetuseestaesisecunivsedessescuauds 25 cdgag paces htesesasenes 57 65 Sensor Heater Sub Assembly Replacement aaa cece e eee eee ee eee eee ee eee ee eens 59 6 5 1 Removing the Sensor Heater Sub Assembly aaa AKA e eee nne 59 6 5 2 Installing th
16. Troubleshooting 5 4 Sensor Heater Wiring As an aid in following the troubleshooting procedures described in this chapter the wiring connections for the FGA 311 sensor heater sub assembly are shown in Figure 13 a o m w BA lt w m N N m Color Description Black 02 Pink O2 Yellow TC Red TC Red Heater Red Heater OSS Figure 13 Sensor Heater Connections 5 5 Temperature Problems If the FGA 311 has difficulty in achieving or maintaining the normal operating temperature of 700 C the problem will be indicated in two ways the red fault LED located on the printed circuit board will begin to flash e if the FGA 311 RS232 interface is connected to a computer the standard measurement screen will show one of the built in error messages Proceed to the appropriate sub section for detailed information on specific temperature problems 46 FGA 311 User s Manual Chapter 5 Troubleshooting 5 5 1 ER2 Error Code When the ER error code is generated the red fault LED on the printed circuit board will begin to flash in groups of two flashes each and the following message screen is sent to the computer via the RS232 interface ER2 20 93 O2 700 0C ER2 replaces RUN on the measurement mode screen Although as long as three hours may be required to achieve a stable output the FGA 311 should reach normal operating temperature in
17. before attempting to calibrate the oxygen sensor 4 5 1 Calibrating with the Manual Switches To calibrate the analyzer with the manual switches located on the FGA 311 circuit board complete the following steps Note See Operation and Programming on page 17 for general information on using the manual switches 1 For optional AIR calibration establish a flow of atmospheric air into the calibration port for at least five minutes at a flow rate of 1000 cc min 2 SCFH This air may be obtained by tapping a line off the reference air source See Figure 7 on page 16 for a suggested piping arrangement 2 Perform optional AIR calibration as follows Set Mode Switch S1 to position 1 AIR and wait for the output reading to stabilize at 20 93 b Push CAL Switch S3 and hold until the green range LED s begin to blink about five seconds c When the green LED stops blinking about 30 seconds the calibration is complete Press CAL Switch S3 and hold for 5 seconds until the LED s stop blinking to EXIT programming mode d Verify that the output reading of the analyzer indicates an oxygen level of 20 93 0 1 3 Stop the flow of atmospheric air to the calibration port and begin the flow of the chosen calibration gas Allow this flow to continue for at least five minutes at a flow rate of 1000 cc min 2 1 SCFH 4 Perform the GAS calibration as follows a Set Mode Switch S1 to position 2 GAS b Push CAL Switch S3 and hold until th
18. calibration flow from 1000 cc min to 1500 cc min If the reading is closer to the span value continue to increase the flow If the reading remains unchanged look for another reason FGA 311 User s Manual 51 Chapter 5 Troubleshooting 5 7 1 ER1 Error Code When the ERI error code is generated the red fault LED on the PC board flashes in groups of one flash each and the following message screen is sent to the PC via the RS232 interface ER1 20 93 O2 700 0C ER1 replaces RUN on the measurement mode screen Note The actual Sensor Failure message only appears on the multi line diagnostic PC screen If this message is displayed on the screen complete the following troubleshooting steps WARNING Disconnect the main power from the unit and allow at least two hours for the system to cool down before proceeding with the following steps 1 Check the oxygen sensor as follows a Remove the electrical connector from the end of the sensor heater sub assembly see Figure 13 on page 46 b Using a digital multimeter measure the resistance between the oxygen sensor connections pins 1 and 2 on the sensor heater sub assembly connector IMPORTANT Do not measure the oxygen sensor resistance on the loose connector which contains the wires going to the PC board c Ifthe reading indicates an open circuit the oxygen sensor is defective and the entire sensor heater sub assembly must be replaced see Sensor Heater Sub Assembly Replacement on
19. ceu ai casa ER dq PONATUR 14 Calibration TR TERRENI TITTEN TT 22 23 dizit ia PP aaa Hm 17 37 OG PR 22 25 Oxygen Serisgl icu d eod kk AW ARCADE A 40 Rande odsesexaseke isa y e s RR 22 Calibration Gas COMPOSIHON s srce stenene Peeters P Osa xd 3T FOW BAG os cios coe 4 979 KARGA KA 38 PlsrnbDIbiQoa o scite opa od uri deme Ws ps 15 CE Mark Compliance sexuel er RAE TRES 79 Circuit Board Replacing 245 ss au Seas AERE DRE s Soros i 60 Common Problems Avoiding 17 D Data Record General Information 14 522 da C ee 81 Sensor Calibration 522a RU PRI ERES RETE 82 SENSOR TESIS vi uoa v utei ek v 3 dores m LAS 82 User Settings does so am dee 3 b eoa BAS 81 USINO se Ae gala aie ha cosa as ws Unahan E ana 19 Date of Public aUDIio x 3 obi gins eget eae Rhee ee i Diagnostics Page oe ies re xx En ER RR Yn 45 Document Number 9 4c ces cer e rms 1 Duty Cycle Setting iupra REESE Rs 85 E EMC Directive s eri dou be ed bana Saat bara 79 Enclosure Cover Removal 2224 v ER EE ari is 56 j ECTS 1 Environmental Compliance vi EPROM Replacing a5 e ne awa d e aware na 62 FGA 311 User s Manual Index Error Codes ERL PC seus APAPAP PA TET SPA PE oes 52 PRE P a kaaway 47 AA PAA AAO AN AO 48 zo A pe PNP um 49 LIEUNG s sg Ba a DA do ca ee ao dC ore 44 Error Handling sio rd REC NY 28 EXTRA MENU S so haaa eoo Nha Gua Paa sees 27 F Flange Options n on nananana naaa 9 F
20. its normal operating temperature of 700 C Then the fault light will go out and the range indicator will glow steadily 18 FGA 311 User s Manual Chapter 3 Operation and Programming 3 4 Taking Measurements After the FGA 311 has warmed up the voltage output of the zirconium oxide oxygen sensor will vary logarithmically with the oxygen concentration in the flue gases according to the Nernst equation see The Nernst Equation on page 69 for details E mV 48 274 e log gt 1 2 In Equation 1 E is the voltage in millivolts generated by the sensor at an operating temperature of 700 C The built in thermocouple temperature sensor in the FGA 311 automatically adjusts the constant used in the Nernst equation to reflect the precise actual temperature of the oxygen sensor In addition the non linear output voltage signal generated by the oxygen sensor is internally converted into a linear 4 20 mA output current signal which is sent to pins 4 and 5 of terminal block TB2 The 4 20 mA current range corresponds to a flue gas oxygen range of 0 to the programmed Oy range 5 10 or 25 By connecting a digital ammeter or a recording device to these terminals the oxygen content of the flue gases may be continuously monitored 3 5 Data Records Data Records on page 81 provides several tables for entering all of the relevant data pertaining to the installation and programming of the FGA 311 Be sure to maintain the ac
21. menu e ERI the Sensor Failure error message ER2 the Warning Warming Up error message ER3 the Open Thermocouple error message e ER4 the Heater Failure error message When all of the desired error handling options have been set press ESC to return to run mode or proceed to the next section to continue programming the EXTRA menu Proceed to the desired section s now to set any or all of the available error handling functions ERI the Sensor Failure error message ER1 ER2 ER3 ER4 Make sure ER1 is highlighted and then press ENTER Proceed to either the Disable ERI or Set ERI prompt ER1 OFF ER1 SET To disable ER1 make sure ER1 OFF is highlighted and then press ENTER Press Disable ER1 BACKSPACE to back up one menu level ER1 OFF ER1 SET To set ER1 press SPACE to select ER1 SET and press ENTER SET ER1 ER1 xx x mA Enter the desired value and press ENTER Press BACKSPACE to back up one menu level 28 FGA 311 User s Manual Chapter 3 Operation and Programming 3 9 4b Error Handling Set Up cont ER2 the Warning Warming Up error message ER1 ER2 ER3 ER4 Press SPACE to select ER2 and then press ENTER Proceed to either the Disable ER2 or Set ER2 prompt ER2 OFF ER2 SET To disable ER2 make sure ER2 OFF is highlighted and then press ENTER Press Disable ER2 BACKSPACE to back up one menu level ER2 OFF
22. on page 56 WARNING Disconnect the main power from the unit and allow at least two hours for the system to cool down before proceeding with the following steps 2 Pull the 1 8 black calibration gas hose off the calibration gas fitting on the sensor heater sub assembly 3 Pull the 6 wire connector off the end of the sensor heater sub assembly 4 Grasp the black plastic block at the end of the sensor heater sub assembly and turn it counterclockwise until it comes free from the threads in the base of the enclosure CAUTION The exposed ends of the oxygen cell are easily damaged if they strike a hard surface Also do not handle the exposed ends of the oxygen cell with bare fingers as deposits of skin oils and or salts may seriously impair sensor operation 5 Carefully pull the sensor heater sub assembly straight out of the enclosure Proceed to the next section for instructions on installing the sensor heater sub assembly FGA 311 User s Manual 59 Chapter 6 Service and Maintenance 6 5 2 Installing the Sensor Heater Sub Assembly Refer to Figure B 4 in Appendix B for an illustration of the sensor heater sub assembly To install the new assembly refer to Figure 16 on page 58 and complete the following steps 1 Carefully slide the sensor heater sub assembly straight into the opening at the base of the enclosure CAUTION The exposed ends of the oxygen cell are easily damaged if they strike a hard surface Also do not hand
23. on the end of the sensor heater sub assembly and proceed to step 3 3 If sufficient warm up time has been allowed and the heater is good then the problem is the result of faulty wiring or a defective printed circuit board Proceed as follows a Refer to Installation on page 7 including the wiring diagram in Figure 6 on page 13 and to Figure 13 on page 46 Make sure that all of the wires have been connected to the proper terminal blocks Also carefully inspect the wiring for shorts and be certain that all of the cable connectors are properly seated in their terminal blocks Lastly verify that each individual lead is still firmly seated in its connector b Ifno wiring problems were discovered in the step above the circuit board is defective and it must be replaced see Printed Circuit Board Replacement on page 60 FGA 311 User s Manual 47 Chapter 5 Troubleshooting 5 5 2 ER3 Error Code When the ER3 error code is generated the red fault LED on the printed circuit board will begin to flash in groups of three flashes each and the following message screen will be sent to the PC via the RS232 interface ER3 20 93 O2 700 0C ER3 replaces RUN on the measurement mode screen Note The actual Open Thermocouple message will appear on the multi line diagnostic PC screen If this message is displayed on the screen complete the following troubleshooting steps WARNING Disconnect the main power from the unit and allow at least
24. operating temperature 650 to 1100 C of the sensor the oxygen molecules in the atmospheric reference air 20 93 oxygen are electrochemically reduced at the inner electrode The resulting oxygen ions seek an equilibrium with the lower oxygen concentration on the sample gas side of the sensor by migrating through the porous ceramic toward the outer electrode Sleeve Packing Screw Packing Oxygen Cell Figure 2 The FGA 311 Oxygen Sensor FGA 311 User s Manual 3 Chapter 1 General Information 13 The Oxygen Sensor cont At the outer electrode the oxygen ions give up their extra electrons and revert to oxygen molecules before being swept away by the flue gas stream This exchange of electrons at the electrodes generates a voltage gradient across the sensor See Figure 3 The lower the concentration of oxygen in the flue gases the greater the rate of ion migration through the ceramic and the higher the resulting voltage gradient across the sensor In fact the sensor s voltage output rises logarithmically as the percentage of oxygen in the flue gases decreases This enables the FGA 311 to accurately measure very small levels of oxygen in the flue gases Oxygen ions migrate through the Zirconium Oxide from Inside to Outside
25. page 59 d Ifthe oxygen sensor is good reinstall the connector on the end of the sensor heater sub assembly and proceed to step 2 2 Check the wiring and the printed circuit board as follows a Carefully inspect the connector at terminal block J2 on the printed circuit board for shorts and or wires that are not securely seated in the connector Pay particular attention to the oxygen sensor leads at pins 3 4 of this connector b Carefully inspect the connector on the end of the sensor heater sub assembly for shorts and or wires that are not securely seated in the connector Pay particular attention to the oxygen sensor leads at pins 1 2 of this connector c If no wiring problems were discovered in the step above the circuit board is defective and must be replaced see Printed Circuit Board Replacement on page 60 52 FGA 311 User s Manual Chapter 5 Troubleshooting 5 7 2 Oxygen Percentage Always Reads 20 93 This condition is somewhat unusual and it is probably caused by a leak in the plumbing a defect in the printed circuit board or defective wiring To isolate the problem complete the following steps 1 A leak in the plumbing may cause the reference air to become contaminated with the process flue gases When the zirconium oxide oxygen sensor has the same oxygen content on both sides of the cell its output will be 0 0 mV which will generate a 4 20 mA signal that converts to 20 93 oxygen Find and correct any plum
26. selected above the output display will constantly show the last good reading until the UNFREEZE option is selected in this sub menu 3 9 4e Setting the Response Time The response time of the FGA 311 may be adjusted using this sub menu A shorter response time will provide by more accurate data by updating the display more frequently but a longer response time will provide a more stable display that is free from flicker COM ERR PID FRZ RESP OFST Press SPACE to select RESP and then press ENTER RESP xx Seconds Enter the desired response time values from 1 to 30 seconds are acceptable and press ENTER Press ESC to return to run mode or return to a previous section to continue programming the PID sub menu FGA 311 User s Manual 33 Chapter 3 Operation and Programming no content intended for this page 34 FGA 311 User s Manual Chapter 3 Operation and Programming Shift D Hyperterminal m Diagnostics Page XXX O AIR 20 93 O2 xxx xC GAS x xx9602 XXX XC Connection 700 C ER1_OFF ER1_SET ER1 xx x mA ER2_OFF TRIM_O2 TRIM_O2 mA 4 20
27. two hours for the system to cool down before proceeding with the following steps 1 Pull the connector from the end of the sensor heater sub assembly Using a digital multimeter measure the resistance between the two thermocouple leads pins 3 and 4 on the sensor heater assembly If the reading indicates an open circuit the thermocouple is defective and the sensor heater sub assembly must be replaced see Sensor Heater Sub Assembly Replacement on page 59 If the thermocouple does not show an open circuit proceed to step 2 IMPORTANT Do not measure the thermocouple resistance on the loose connector which contains the wires going to the PC board 2 Ifthe thermocouple is good then the problem is the result of faulty wiring or a defective printed circuit board a Refer to Installation on page 7 including the wiring diagram in Figure 6 on page 13 and to Figure 13 on page 46 Make sure that all of the wires have been connected to the proper terminal blocks Also carefully inspect the wiring for shorts and be certain that all of the cable connectors are properly seated in their terminal blocks Lastly verify that each individual lead is still firmly seated in its connector b Ifno wiring problems were discovered above the circuit board is defective and it must be replaced see Printed Circuit Board Replacement on page 60 48 FGA 311 User s Manual Chapter 5 Troubleshooting 5 5 3 ER4 Error Code When the E
28. 1 Explosion Proof Assembly Drawing 705 764 rev N Sheet 3 75 e Figure 21 FGA 311 Printed Circuit Board Drawing 703 1216 revJ 76 e Figure 22 FGA 311 Heater Assembly Drawing 705 766 rev G TI e Figure 23 RS232 Cable Assembly Drawing 704 668 rev C 78 FGA 311 User s Manual 71 72 no content intended for this page FGA 311 User s Manual Appendix B FGA 311 Drawings 1 REVISIONS REV Eco DESCRIPTIONS DWN CKD APVO M p REPLACED FORMAT amp UPDATED PER ECO JCF DMS GT 6 24 04 8 4 04 8 4 04 PMH os DS N 05626 UPDATED PER ECO 8 8 05 eros 8 9 05 TABLE 1 SENSOR LENGTH DIM A 19 2 meters am SEENOTE2 6 z o 400 tong SEENOTE2 21 c 1016 ATTACH OTHER END TO Z GAS FITTING ITEM 9 G2 3 PLACES a o ai RIOR E AS 5 5 S log Qo n I9 HI sa 19 INCH PROBE SHOWN R A OO E E5277 RSS d NANANA NN LIN Ss SCA C lt i 4 Wye NN SECTION A A W we SEE NOTE 2 COATES 4 7 e X Ns ng RS BS HS M x Sx Ses X KODAK EA x v G6 44 8 SEE NOTE 3 1 METER PROBE SHOWN TORQUE 80 F Q3 2 PLACES 2 2 PLACES FGA 311 Weatherproof Assembly Draw Figure 18 NOTES NUT amp F
29. 2 FGA 311 User s Manual Chapter 5 Troubleshooting Chapter 5 Troubleshooting 5 1 Introduction The FGA 311 In Situ Flue Gas Oxygen Transmitter has been designed to overcome most of the problems commonly associated with monitoring flue gases However because of the corrosive and extreme conditions under which the instrument must operate some difficulties may still be encountered Procedures for resolving such situations are discussed in this chapter If the required information can not be found in this chapter contact GE for assistance Two modes of error reporting have been built into the FGA 311 software e a fault indicator that is mounted on the printed circuit board an error message system that is accessible via the RS232 interface Additional troubleshooting clues may be found by observing any unusual readings from the 4 20 mA output on terminal block TB2 WARNING To ensure safe operation of the FGA 311 the instrument must be installed and operated as described in this manual In addition be sure to follow all applicable local safety codes and regulations for installing electrical equipment WARNING The procedures in this manual should be performed only by trained service personnel FGA 311 User s Manual 43 Chapter 5 Troubleshooting 5 2 Troubleshooting Guide The most commonly encountered indicators of an operational problem with the FGA 311 are listed in Table 4 Refer to this table as the initial source of
30. 311 must be maintained at its normal flow rate throughout the calibration procedure To accurately calibrate the FGA 311 a calibration gas flow rate of approximately 1000 cc min 2 1 SCFH is required Flow rates lower than this may result in unstable readings and higher flow rates may cause excessive cooling of the oxygen sensor CAUTION Do not use a calibration gas flow rate higher than 2000 cc min 4 2 SCFH Such flow rates will cool the oxygen sensor and lead to inaccurate readings or even cause damage to the sensor 38 FGA 311 User s Manual Chapter 4 Calibration 44 The Calibration Gas System cont lt x E Z LU Cc c D O D am D O 10 15 PERCENT OXYGEN Figure 11 Oxygen Sensor Calibration Output FGA 311 User s Manual 39 Chapter 4 Calibration 4 5 Calibrating the Oxygen Sensor To calibrate the FGA 311 oxygen sensor either of the two programming methods described in Operation and Programming on page 17 manual switches or a PC connection may be used Proceed to the appropriate section for the chosen programming method Note Make sure that the analyzer has been powered ON and has been allowed to warm up for at least one hour
31. B2 on the printed circuit board Also verify that positive contact is being made by the leads to pins 1 3 of this terminal block If these connections are secure proceed to the next step At the PC end of the RS232 cable make sure that the DB9 connector is securely installed on the serial port of the computer Refer to the computer s documentation and the FGA 311 RS232 interface parameters see RS232 Serial Port Settings on page 24 If the RS232 interface has been properly established in accordance with these requirements proceed to the next step Note Frequently reversing leads 2 and 3 of the RS232 connection on terminal block TB2 will solve this type of problem 3 The EPROM is defective and must be replaced see EPROM Replacement on page 62 5 7 Oxygen Reading Problems The generation of inaccurate oxygen readings by the FGA 311 is indicated in two ways the red fault LED located on the printed circuit board will begin to flash and the ER1 error code is generated on a PC that is connected via the RS232 serial port unusual or unexpected oxygen percentages will be read at the 4 20 mA output terminals pins 4 5 on terminal block TB2 Proceed to the appropriate sub section for detailed information on specific oxygen reading problems Note The most common reason that the O reading is not correct high or low is because the calibration gas has not fully displaced the process gas from the sensor area Increase the
32. CABLE ASSEMBLY DB9F PLACE BACKSHELL OVER CONNECTOR AND CLOSE USING INCLUDED HARDWARE TH FLYING LEADS SLIDE LABEL ONTO CABLE AND SHRINK IN PLACE EAM 5 10 96 PHP 6 11 96 TERMINATE REMAINING END PER DRAWING OS KCP 40 96 PF SIZE DRAWING NUMBER maa B 701 668 JC WEE Mi yee 3 e 1 Figure 23 RS232 Cable Assembly Drawing 704 668 rev C FGA 311 User s Manual 78 Appendix C CE Mark and Regulatory Compliance AppendixC CE Markand Regulatory Compliance C 1 CE Mark Compliance For CE Mark compliance the FGA 311 must meet both the EMC and LVD directives WARNING CE MARK COMPLIANCE IS REQUIRED FOR ALL UNITS INSTALLED IN EU and EEA COUNTRIES C 1 1 EMC Directive WARNING TO MEET CE MARK REQUIREMENTS YOU MUST SHIELD AND GROUND ALL ELECTRICAL CABLES AS DESCRIBED IN THIS SECTION see Table 6 Note f you follow the instructions in this section your unit will comply with the 2004 108 EC EMC Directive Table 6 Wiring Requirements for CE Mark Compliance Connection Termination Modification Power Analog Output 1 When connecting the line power analog output cable select the cable entry closest to the terminal blocks Use shielded cable such as GE P N X4 or equivalent to connect the line power and the 4 20 mA analog output device to the FGA 311 Terminate the shield to the recommended cable gland GE P N 419
33. ER xxx Seconds Enter the desired integration time value and press ENTER Press ESC to return to run mode or proceed to the next section to continue programming the PID sub menu O set the overheat value SET P O DEFAULT Press SPACE to select O and then press ENTER P xxx Degrees C Enter the desired overheat value and press ENTER Note The overheat value should be set to the highest process temperature acceptable values are 600 1200C The default value is 820 C Press ESC to return to run mode or proceed to the next section to continue programming the PID sub menu DEFAULT restore the factory default SET P and O values SET P O DEFAULT To restore the default values press SPACE to select DEFAULT and press ENTER Press ESC to return to run mode or proceed to the next section to continue programming the EXTRA menu 32 FGA 311 User s Manual Chapter 3 Operation and Programming 3 9 4d Freeze a Reading In some situations it may be helpful to freeze an output reading for viewing at a more convenient time To accomplish this perform the following steps COM ERR PID FRZ RESP OFST Press SPACE to select FRZ and then press ENTER FREEZE UNFREEZE Press SPACE to select the desired menu choice and press ENTER Press BACKSPACE to back up one menu level Press ESC to return to run mode If FREEZE was
34. ERO seek 15 TBICODDBCBOI sus Eye E 12 TBZ Connections sree cire RC Y oe n RR 14 Terminal DB ce ie GWA ALAKDAN DA ASG ENG 27 Testing Heater oed da bate kot eti eo e rie kah 47 Oxygen SansDI s Love DARAAN PADA eas 52 Thermocouple 4 waaa eked RR dane REY RR NGA 48 Thermocouple TESNO Tr 48 VICIDIO ane ae aeo TE st kA GNG coder op Pares 15 TRIM MENU i uo eek erg r ace 26 TRIM 02 SUN 65e oe ER e P rn 22 26 FGA 311 User s Manual Index Troubleshooting Diagnostics Page sud eoss ua PbobesqQer dues ds 45 UNOS ais depu tans 3 b door CRX docui oa dues 44 Output Problems aces eer n n 50 Oxygen Reading Problems 51 Temperature Problems 46 Wiring Problems isse oes RE ERRRRYS 46 W Warm UD TIME 2 26 e ES GRACE KNA KAG anes AA 17 Walang ssa Pm 91 WEEE DIKECING sii hats igre hhahaha eR Rd Gs vi Wiring Analog OUUDUE oes soa verse ku erates chan 14 CE Mark COMmplanCe 6 44454 sar n ASAP T9 Heater a 15 Line Power cess Kaka Ka eens DRE Rowe AG 12 Oxygen Sensof poe Dama cto KANA KKK bend KANYA 15 RS232 Interface se oues cheb req ERE PRSE RS 14 Mermoco plE APAPAP dE ERR ES 15 FGA 311 User s Manual 89 Index no content intended for this page 90 FGA 311 User s Manua Warranty Warranty Fach instrument manufactured by GE Sensing is warranted to be free from defects in material and workmanship Liability under this warranty is limited to restoring the instrumen
35. ERRULE OF ITEM 17 1 FULLY SEAT ITEM 5 OR 20 TO ITEM 1 SEE NOTE 4 WPF SHOWN 2 FINAL ASSEMBLY POSITION OF ENCLOSURE ITEM 1 AND VENT HOLES OF FILTER TIP ITEMS 6 amp 21 TO BE UNISS CE e ORIENTED APPROXIMATELY 180 FROM VENT FITTING ITEM 18 AS SHOWN DIMENSIONS ARE IN INCHES 1100 Technology Park Dr 3 ASSEMBLE SET SCREW ITEM 22 INTO ENCLOSURE ITEM 1 WITH LOCTITE ITEM 43 ON BOTTOM HALF OF THREADS FACTIONS Coos ANGLES LT N ae TO DIMENSION SHOWN APPLY THREADLOCKER ITEM 23 TO THREADS OF ITEM 13 Pai NM APPO FGA311 4 REMOVE NUT AND FERRULES PART OF ITEM 17 PLACE IN PLASTIC BAG SHIP LOOSE IN ENCLOSURE ITEM 1 ASSEMBLY 5 SECURE ITEM 44 COMPRESSION CAP ONTO ITEM 17 COPYRIGHT 1997 GENERAL ELECTRIC CO IATION THIS DRAWING RMA 6 FOR UNITS WITH SERIAL NUMBER 172 AND EARLIER USE 2 OF P N 410 444 O RING VITON 2 017 WHEN REPLACING ITEMS 4 19 39 OR 40 GENER NANO MAY NOT BE D TO OTHERS EXCEPT WITH THE WRITTEN PERMISSION OF GENERAL FGA 311 User s Manual 73 Appendix B FGA 311 Drawings SEE NOTE 5 ORIENTATION OF HOLES IN ITEM 6 AND 21 SEE NOTE 2 0N DIES ION jepoy SHOA AVHLTYM soTwanvnva ISSN LZZ NALIWVNYd mmm O IN SITU ANALYZER TRANSFORMER T1 REF POSITION LABEL ON WALL OF ITEM 1 ABOVE FI FUSE Figure 19 FGA 311 W
36. GE Measurement amp Control Gas Analysis FGA 311 User s Manual a 910 160 Rev E imagination at work J uly 2012 FGA 311 In Situ Flue Gas Oxygen Transmitter User s Manual 910 160 Rev E July 2012 www ge mcs com 2012 General Electric Company All rights reserved Technical content subject to change without notice no content intended for this page Contents Chapter 1 General Information a a AAO 1 1 2 Principlesof OPEN T EmRTTMIPT 3 1 3 The Oxygen Sensor PEP PNTA PA PEPE PAP PNP PPO PSU RATE PANER UM DEDE 3 1 4 The Heater Control CIICUIo 2 rrr uuu KANAN PN LING KG GAGA NGAGE AKDA ANGER Pass RI EDAPENEQE DR CR Ru 5 Chapter 2 Installation 2 reo HCL AA AA AA PA PAP PO TM 7 22 Unpackno mie oigsascctedeacuteaserut ds acwadueanauce taesecedscdeededncapednasesodoantarsenesddenade 7 2 3 Line Power Requirements a BAGBAG R4 xu eR RR ERR E TW CHER RR E nde eRe hewn 8 ZA Selecting he Site iiec esosuecteertLerh e eben ERR ER EFC DEL DERE pp ECCL bI Ed ae ae OC Pn addas 8 25 Bench TSONG sind BAGAN ua ER REMO D RATE A EO RUD A ac mesa E o er aeta DR E E eain 9 205 Mo ntng the RITIVZBE usi E paa aun te ied ades Lan Eco Roe EAE ER auc psp Re Kr AG AGANE Ra run ME E adpE d 9 21 7 WING ANA ZB akma AD obo Enable a d une kaa ALAGANG sah haka GAAN EAT GANA 12 2 7 1 Wiring the Line Power 02 0 naa 12 231 Wiring thie Control Signals cx naaa Kama E RE Kam GB ARDE ne een otis ccarksexsaebeweerd
37. NEER 12714756 02830 E M 9 5 96 C MARIANO CHECKED 12718796 02609 PANAMETRICS WALTHAM MASS 02154 3497 HEATER SUB ASSEMBLY DRAWING NUMBER 705 766 FGA311 NONE DO NOT SCALE DWG sheer 10F1 3 2 1 705 766_rev G ing FGA 311 Heater Assembly Drawi Figure 22 PATA Appendix B FGA 311 Drawings REVISIONS WIRING DIAGRAM DESCRIPTIONS DWN SE KA RELEASED TO ECO CDNTRHI mm WHT RX Receive Data 3 02850 REVISED PER ECO TENA E RED TX Transmit Data REVISED PER ECO DV GRN GND Ground SULDER DRAIN WIRE HERE PIN 6 STRIP 25 AND TIN TRIM BRAID FUIL AND VEVA T BLACK WIRE FLUSH DO NOT CUT DRAIN SOLDER SIDE PLACE 1 5 SLEEVING 12 2 00 704 668 3 POSITION ANB SHRINK IN PLACE A LENGTH IN INCHES 3 NOTES STRIP CABLE JACKET 7 8 INCH TRIM FOIL AND BLACK WIRE FLUSH TO CABLE JACKET TRIM 1 4 OFF EACH CONDUCTOR PLACE 1 4 LING SLEEVE ITEM 18 410 039 OVER EACH CONDUCTOR UNLESS OTHERWISE SPECIFIED GE Sensing PLACE 5 8 LUNG SLEEVE ITEM 12 410 039 OVER DRAIN WIRE EE AP 1100 Technology Park Drive STRIP TIN CONDUCTORS TO 1 8 INCH ENSURE ITEM 5 IS TIN PLATED FRACTIONS DECIMALS ANGLES Bilerico MA wees USA SOLDER PER WIRING DIAGRAM oS SLIDE SLEEVING OVER SOLDER CONNECTIONS SHRINK ALL SLEEVES IN PLACE SURFACE ENS S
38. NG TEMP_RNG Make sure O2 RNG is selected and then press ENTER 5 10 25 Press SPACE to select the desired oxygen range and press ENTER Press BACKSPACE to return to the RNG menu FGA 311 User s Manual 25 Chapter 3 Operation and Programming 3 9 3 TRIM Menu Use the following procedure to move through the TRIM menu RUN 20 93 02 700 0C Press ESC to move from run mode to the User Program Note While in the TRIM menu you may return to run mode at any time by pressing the ESC key OPTS TRIM EXTRA Press SPACE to select TRIM and then press ENTER 3 9 3a Trim Oxygen Output TRIM O2 TRIM TEMP Make sure TRIM C2 is highlighted and press ENTER Note For the TRIM O2 function always adjust the 4 mA setting before the 20 mA setting This will ensure that the instrument operates at optimum accuracy TRIM O2 mA 4 20 Make sure 4 is highlighted and then press ENTER 4mA O2 xxx ADJUST Using 4 and adjust the value to obtain an output signal of 4 mA Press ENTER to accept the new value Press BACKSPACE to back up one menu level TRIM O2 mA 4 20 Press SPACE to select 20 and then press ENTER 20mA O2 xxx ADJUST Using and adjust the value to obtain an output signal of 20 mA Press ENTER to accept the new value Press DBACKSPACE twice to return to the TRIM menu Press ESC to return to run mode or proceed to the next section to continue prog
39. R4 error code is generated the red fault LED on the printed circuit board will begin to flash in groups of four flashes each and the following message screen will be sent to the PC via the RS232 interface ER4 20 93 O2 700 0C ER4 replaces RUN on the measurement mode screen Note The actual Heater Failure message only appears on the multi line diagnostic PC screen If this message is displayed on the screen complete the following troubleshooting steps WARNING Disconnect the main power from the unit and allow at least two hours for the system to cool down before proceeding with the following steps 1 Pull the connector from the end of the sensor heater sub assembly Using a digital multimeter measure the resistance between the two heater connections pins 5 and 6 on the sensor heater sub assembly The reading should be about 160 ohms for a 110 VAC heater or 380 ohms for a 220 VAC heater If the reading is significantly higher than this the heater is defective and the sensor heater sub assembly must be replaced see Sensor Heater Sub Assembly Replacement on page 59 IMPORTANT Do not measure the thermocouple resistance on the loose connector which contains the wires going to the PC board 2 Ifthe heater appears to be good reinstall the connector on the end of the sensor heater sub assembly The problem is likely the result of faulty wiring or a defective printed circuit board and the following steps should be completed a
40. Records D 1 General Information Enter the general information about your FGA 311 and its installation in Table 7 Table 7 General Information Current Value Installation Date Unit Model Number Unit Serial Number Line Voltage Reference Air Composition Reference Air Flow Rate Calibration Gas Composition Calibration Gas Flow Rate Application Description D 2 User Settings Enter the current user settings that are programmed into the FGA 311 User Program in Table 8 Table 8 User Settings HY HY p ER1 SET ER2 SET ER3 SET ER4 SET Loo FGA 311 User s Manual 81 Appendix D Data Records D 3 Test and Calibration Data The zirconium oxide oxygen sensor in the FGA 311 should be tested and calibrated on a regular schedule Enter your test and calibration data in Table 9 and Table 10 respectively Table 9 Oxygen Sensor Tests TestDate Reut Table 10 Oxygen Sensor Calibrations Calibration Date Result 82 FGA 311 User s Manual Appendix D Data Records D 4 Service Record All service procedures excluding normal routine maintenance performed on the FGA 311 should be recorded in Table 11 Table 11 Service Record Date Service Performed FGA 311 User s Manual 83 84 no content intended for this page FGA 311 User s Manual Appendix E Advance
41. Refer to Installation on page 7 including the wiring diagram in Figure 6 on page 13 and to Figure 13 on page 46 Make sure that all of the wires have been connected to the proper terminal blocks Also carefully inspect the wiring for shorts and be certain that all of the cable connectors are properly seated in their terminal blocks Lastly verify that each individual lead is still firmly seated in its connector b If no wiring problems were discovered in the step above the circuit board is defective and it must be replaced see Printed Circuit Board Replacement on page 60 FGA 311 User s Manual 49 Chapter 5 Troubleshooting 5 6 Output Problems If one or more of the analyzer s outputs is completely non functional proceed with the instructions in this section 5 6 1 All Outputs Inactive If the analyzer is completely inactive i e there is no RS232 or 4 20 mA signal output and all of the LEDs on the printed circuit board are OFF there is a power failure in the system Proceed as follows IMPORTANT This symbol indicates Caution risk of electric shock 50 N Check the input power to the PC board as follows d Remove the plastic cover from the fuse holder Use a digital AC voltmeter to check the power into the printed circuit board Place one of the voltmeter leads on the ground terminal inside the FGA 311 enclosure and place the other voltmeter lead on the end of the fuse holder closest to terminal blo
42. TVICERECOLO ues coo Y NENG boe ER Valen ep e wel Co I edd EN e RS dcn 83 Appendix E Advanced Calibrations El Dilly Cycle ONset PDT 85 FGA 311 User s Manual V Contents no content intended for this page vi FGA 311 User s Manual Preface Information Paragraphs Note paragraphs provide information that provides a deeper understanding of the situation but is not essential to the proper completion of the instructions Important paragraphs provide information that emphasizes instructions that are essential to proper setup of the equipment Failure to follow these instructions carefully may cause unreliable performance e Caution paragraphs provide information that alerts the operator to a hazardous situation that can cause damage to property or equipment e Warning paragraphs provide information that alerts the operator to a hazardous situation that can cause injury to personnel Cautionary information is also included when applicable Safety Issues WARNING Itis the responsibility of the user to make sure all local county state and national codes regulations rules and laws related to safety and safe operating conditions are met for each installation Auxiliary Equipment Local Safety Standards The user must make sure that he operates all auxiliary equipment in accordance with local codes standards regulations or laws applicable to safety Working Area WARNING Auxiliary equipment may have both manual
43. about 30 minutes When the proper operating temperature has been reached the ER2 error message is replaced by the normal measurement screen Note The actual Warning Warming Up message only appears on the multi line diagnostic PC screen If this message is displayed on the screen complete the following troubleshooting steps 1 Allow at least thirty minutes for the unit to warm up If the ER2 error message persists beyond the 30 minute warm up time proceed to step 2 2 Usually a defective heater or thermocouple will generate its own error message However it is helpful to verify the integrity of these components now by completing the following steps WARNING Disconnect the main power from the unit and allow at least two hours for the system to cool down before proceeding with the following steps a Pull the connector from the end of the sensor heater sub assembly Using a digital multimeter measure the resistance between the two heater connections pins 5 and 6 on the sensor heater assembly The reading should be about 160 ohms for a 110 VAC heater or 380 ohms for a 220 VAC heater If the reading is significantly higher the heater is defective and the sensor heater sub assembly must be replaced see Sensor Heater Sub Assembly Replacement on page 59 IMPORTANT Do not measure the heater resistance on the loose connector which contains the wires going to the PC board b Ifthe heater appears to be good reinstall the connector
44. and automatic modes of operation As equipment can move suddenly and without warning do not enter the work cell of this equipment during automatic operation and do not enter the work envelope of this equipment during manual operation If you do serious injury can result WARNING Make sure that power to the auxiliary equipment is turned OFF and locked out before you perform maintenance procedures on the equipment Qualification of Personnel Make sure that all personnel have manufacturer approved training applicable to the auxiliary equipment Personal Safety Equipment Make sure that operators and maintenance personnel have all safety equipment applicable to the auxiliary equipment Examples include safety glasses protective headgear safety shoes etc Unauthorized Operation Make sure that unauthorized personnel cannot gain access to the operation of the equipment FGA 311 User s Manual V Preface Environmental Compliance Waste Electrical and Electronic Equipment WEEE Directive GE Measurement amp Control is an active participant in Europe s Waste Electrical and Electronic Equipment WEEE take back initiative directive 2002 96 EC The equipment that you bought has required the extraction and use of natural resources for its production It may contain hazardous substances that could impact health and the environment In order to avoid the dissemination of those substances in our environment and to diminish the press
45. bing leaks that could cause the above contamination to occur If the problem persists proceed to the next step Check for shorts in the oxygen sensor wiring at pins 1 and 2 on the sensor heater sub assembly connector and at pins 3 and 4 of terminal block J2 on the printed circuit board If no plumbing leaks or oxygen sensor wiring shorts were found remove the connector from the end of the sensor heater sub assembly Using a digital voltmeter measure the voltage across pins 1 and 2 on the sensor heater sub assembly not the loose connector If this voltage is 0 0 mV the 20 93 oxygen reading is valid If some non zero voltage is read the printed circuit board is defective and must be replaced see Printed Circuit Board Replacement on page 60 5 7 3 Oxygen Percentage Unchanged for more than 15 Minutes It is possible that the flue gas composition really is this stable However if such is not the case there are two likely causes for this problem 1 The analyzer may have accidentally been left in FREEZE mode Refer to Operation and Programming on page 17 and select the UNFREEZE option from the EXTRA menu If the unit was not in FREEZE mode proceed to the next step The porous filter on the end of the probe assembly may have become clogged If this is the case the probe tip will have to be cleaned or replaced see Probe Tip Replacement on page 55 FGA 311 User s Manual 53 Chapter 5 Troubleshooting 5
46. bly High Temperature 8 Probe Tip Replacing 2a aano 55 Programming Computer Terminal 22252223 5 TIE DAGA 23 Error Handle ssou s osa ssa RAANG BRAD 28 Heater Control s maa ood dor ARA KANA 31 Keystrokes AA Ew iP IRA UU ERE 23 Manual Switches ausa dba wy uA Ga Kawa 20 Methods s aaa bag Pind KG a Hea KA NG Baad KG 19 NCES AN AA 21 Terminal DD v vara 3 vr sa DE ER EE AKA 27 Proportional Band Value 5 31 R Range Calibration 4i es 22 Reference Air Plumbing 13 Ret rn POlCY ss Sees iier Pd et Ud ET PIER I 91 88 RS232 Interface Lal sooo oou PRbATIQEE NSRIES NAT 14 CONMECHONS euer pa d Pasce LABA od ou 24 S Safety Auxiliary Equipment lt 2 ius Seo cena tw es V General Issues a o3os43 x 9 PEORES APA ERA ES V Personal Equipment iu cessa dade e TR V Safety ISSueS AD V Sensor Output Voltage aaa prn ST Sensor Heater Assembly REDIGO es t2abiune eies tedio e heni nea 59 WNO 5 oa pe Sees g das Pda dau NONA DAGA 46 Spare Pares List oou ca aceece v e 2 eo i 64 Specifications FD Ubrial 54 5 diesen ddr geccn p Pd E dod 67 SAC scd dace PA brad 66 PEriGhMadNnCe lt 2hi564ive AGA NBA KASO ALANG 65 PBVSIESI us estero APA APAPAP AA AA 68 Startup Sequence a acces d KKK GWA dees 18 Switches 01 53 gadan EU retusa tacada ais 21 T Taking Measurements 1s serere Rn redu 19 Terminal Blocks J2 CONMECHONS 2 e Sa dp AO ERRAT SC 15 J3 ConnecHoriss ca ec oA H
47. cement cont 6 Apply the thread lubricant to the probe threads and securely tighten the probe tip onto the end of the probe base 7 Reinstall the FGA 311 into the flue wall See Installation on page 7 for specific instructions 8 Reconnect all electrical and mechanical lines to the analyzer body 9 Apply power to the unit and let it heat back up to the normal operating temperature of 700 C This should take approximately thirty minutes Normal operation of the FGA 311 may now be resumed 6 3 Cover Removal and Reinstallation All other field replaceable components are located within the FGA 311 enclosure and removal of the unit need from the flue stack is not required to service these items The first step in replacing these parts is to remove the cover from the enclosure To do so refer to Figure 15 and complete the following steps O Ring Ground Screw a x o Sp TON euS TON POW SYOA o c Sg 2D D un o c o Set Screw Enclosure Figure 15 Cover Removal 56 FGA 311 User s Manual Chapter 6 Service and Maintenance 6 3 Cover Removal and Reinstallation cont 1 Loosen do not remove the locking set screw that is located near one of the slots on the cover IMPORTANT 7hese symbols indicate Caution
48. ck TB1 on the printed circuit board The above test point is the direct input line to the printed circuit board and full line voltage should be present there If there is no voltage at that point check the power source the main disconnect and the connections to terminal block TBI If there is full line voltage reaching the PC board proceed to the next step Check the fuse as follows a c Place one of the voltmeter leads on the ground terminal inside the FGA 311 enclosure and place the other voltmeter lead on the end of the fuse holder farthest from terminal block TB1 on the printed circuit board If full line voltage is not present at the above test point the fuse is defective and must be replaced see Fuse Replacement on page 57 If there is full line voltage at the test point proceed to the next step The presence of full line voltage at both ends of the fuse holder indicates that the proper power is reaching the printed circuit board Therefore the printed circuit board is defective and must be replaced see Printed Circuit Board Replacement on page 60 FGA 311 User s Manual Chapter 5 Troubleshooting 5 6 2 No RS232 Output If the analyzer is operating normally but the RS232 interface is not functioning proceed with the following steps 1 Carefully inspect the RS232 cable connections within the FGA 311 enclosure Make sure there are no shorts caused by faulty wiring at the connector to terminal block T
49. cover as described above Power up the unit and allow it to warm up for at least one hour FGA 311 User s Manual 57 Chapter 6 Service and Maintenance 6 4 Fuse Replacement cont Power Leads Sensor Heater Connector Gas Hose Fuse Fuse Cover Standoff Heater Leads Sensor Heater Assy Standoff Thermocouple Leads Sensor Leads RS23201eads END VIEW 4 20 mA Leads J3 Standoff Gas Hose Sensor Heater Connector Sensor Heater Assy SECTION NSO UA SR SIDEVIEW Sc gar Standoff TB2 Figure 16 Internal View of Enclosure 58 FGA 311 User s Manual Chapter 6 Service and Maintenance 6 5 Sensor Heater Sub Assembly Replacement If either the heater the thermocouple or the oxygen sensor becomes defective the sensor heater sub assembly must be replaced To do so refer to Figure 16 on page 58 and proceed to the next section CAUTION Never disassemble or attempt to repair the sensor heater sub assembly in the field The entire sub assembly must be replaced as a complete unit 6 5 1 Removing the Sensor Heater Sub Assembly Remove the defective sensor heater sub assembly as follows 1 Power down the FGA 311 and allow at least two hours for the unit to cool down to ambient temperature Remove the cover from the enclosure as described in Cover Removal and Reinstallation
50. curacy of this data on a regular basis In the event of problems with the unit the data records may provide valuable information to assist in the troubleshooting procedure 3 6 Menu Map A complete menu map of the FGA 311 built in software is shown in Figure 10 on page 35 Refer to this figure as needed to supplement the step by step programming instructions that follow 3 7 Programming Options The following two methods for programming the FGA 311 In Situ Flue Gas Oxygen Transmitter may be used to navigate through the User Program e manual switches which are located inside the enclosure on the analyzer s printed circuit board ahyperterminal or terminal or computer utilizing the unit s built in RS232 serial interface Note 77e entire EXTRA menu is not accessible via the manual programming switches FGA 311 User s Manual 19 Chapter 3 Operation and Programming 3 8 Programming with Manual Switches Manual programming of the FGA 311 is accomplished with a series of switches and LEDs located on the printed circuit board These components which are shown in Figure 8 may be accessed by removing the cover from the FGA 311 Although the menu map shown in Figure 10 on page 35 does apply to both the manual programming mode and the RS232 programming mode some of the programming options are not available via the manual switches Specifically the entire EXTRA menu can not accessed via the PC board switches
51. d Calibrations Appendix E Advanced Calibrations E 1 Duty Cycle Offset The offset value is subtracted from the Raw O2 mV value with the difference showing in the O2 mV value The amount of duty cycle offset table entries can range from 0 to 5 and they do not have to be entered in any type of order The calculation of the offset value to subtract depends on the following cases 1 One duty cycle offset entry only The offset entry in this case will be used universally that is the same offset will be used no matter what the duty cycle 2 More that one activated entry and measured duty cycle falls between two entered duty cycle values from the table The software will choose the closest duty cycle values above and below the measured duty cycle The offset value will be interpolated based on the chosen entries 3 Measured duty cycle value falls above or below any table value The offset value will clamp to the lowest or highest table entry in terms of duty cycle 4 Noentry activated or whole table de activated The offset value will be zero COM ERR PID FRZ RESP OFST Press SPACE to select OFST and then press ENTER Use Offset Table YES NO Observe the Offset enable Yes No menu and press the D key Run time data should appear or disappear depending on the prior setting Selecting NO from the offset enable choices will give a message of DUTY CYCLE OFFSET TABLE ENABLED No table should app
52. e 21 FGA 311 User s Manual 76 Appendix B FGA 311 Drawings FGA 311 User s Manual 4 3 1 o 300 REF DETAIL A SCALE NONE HEATER WIRES REF REVISIONS REV Eco DESCRIPTIONS DWN cko APvD RELEASED FOR ECO CONTROL 10 1595 6718798 12 18 96 REVISED PER ECO EJM MPT CM 7 1 97 713797 7710 97 REVISED PER ECO EJM MPT JAT 1875797 12 18797 12 16 97 REVISED PER ECO TIP MPT CM 1722798 1 30 98 278798 UPDATED PER ECO JAM 675 00 UPDATED PER ECO JAM UPDATED PER ECO 17 34 t10 440 4 t2 5 WIRING LIST FROM GROUPS a PART NL DESCR HEATER 2 705 766 01 STANDARD d YELLOW 705 766 02 115 VAC 75w DALTON Ce RED 705 766 03 230 VAC 135 DALTON NOTES L HEAT SHRINK ITEM 21 OVER THERMOCOUPLE WIRES AFTER WIRES HAVE BEEN PLACED IN CONNECTOR 2 DIMENSIONS INCHES MM 3 USE 1 16 HEAT SHRINK ON THERMOCOUPLE RED SHRINK ITEM 24 ON RED WIRE P4 BLACK SHRINK ITEM 13 ON YELLOW WIRE HERMOCOUPLE SHEATH REF FOR SCHEMATIC SEE 700 1216 03524 UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANCES ARE FRACTIONS DECIMALS ANGLES zo XX t 06 tw RE SURFACE FINISH V DRAWN ENGI
53. e Sensor Heater Sub Assembly 0 00 c eee NAKA AKN KAKA me 60 6 6 Printed Circuit Board Replacement a c20ssscccodeottcessccd donews KENA KABANG saeeteehewe deena FERAT baeo 60 6 6 1 Removing the Printed Circuit Board 10 cece saa 61 6 6 2 Installing the Printed Circuit Board 32 aka kap Bda waah apak GATE ubt pa GALA ie EEXAVA ERA KAPITAN 61 b 7 EPROM Replacement iissxeeee obrera eer ERR p reriket tre Meee due ET EELEE Wer RE EE DL FREE DRE 62 68 Spare Parts DISE S en peru epus eea eise PA RUE dato DD KR a dra 64 Chapter 7 Specifications JA Performance eere rcv ERRRE RR Ie SE RREFEERISDUE WE E EE ORO EIER GAD eo RE RE eeu 65 TZ erus T nwnET 66 DNE eI ETERNI 67 MAL I EEEE EIE 68 Appendix A The Nernst Equation AA a deed cad ER CUR EE S CRREWE A CUR EO RERO AA D pep IU 69 A2 JEgulibridm CORGIBOTIS oid i edo X a Rap EEEE E E UE E BOUE AC AE RUP x n 69 Pye Wie POA SLL reI 70 Appendix B FGA 311 Drawings Appendix C CE Mark and Regulatory Compliance Cl CE Mark CompliginCess as 244canuciedsacssscenaudaqesduecasueutieda 4hs GA Aah PLANING EEEE 79 CI EMGIDIRECEING 223626 agawa AGANE haa EE dde adden ced Riddle AN an A 79 CAV D DEO VA AA APAPAP AA PA 79 Appendix D Data Records D 1 General Information hh hee ae NA 81 D2 Us rSetnSssesesesd ena vade eer ebt ERR deren crsageel heeded ee LiGweedyeucsdsuddatstekeine LIL IRAN NAA 81 D Test and Calibration Data AN 82 D4 SE
54. e control point back toward the set point within a specified period of time Thus decreasing this integration time reduces the offset more quickly Derivative Action The derivative portion of the control loop applies a corrective signal based on the rate at which the actual temperature is approaching the set point In effect the derivative action reduces overshoot by counteracting the control signal produced by the proportional and integral parameters The heater control circuit is configured at the factory for optimum performance Because of the strong interaction between the three parameters involved properly setting up the PID loop is a very complex matter As a result randomly changing the P I and or O parameters can seriously degrade the performance of the FGA 311 IMPORTANT Always contact GE before attempting to change the default P I or O values FGA 311 User s Manual 5 Chapter 1 General Information no content intended for this page 6 FGA 311 User s Manual Chapter 2 Installation Chapter2 Installation 2 1 Introduction This chapter gives directions for installing and wiring the FGA 311 The following specific topics are included e unpacking the unit e selecting the site mounting the analyzer wiring the analyzer WARNING To ensure safe operation of the FGA 311 it must be installed and operated as described in this manual In addition be sure to follow all applicable local safety codes and regulat
55. e green range LED begins to blink about five seconds c Using ADJ Switch S2 adjust the output reading of the analyzer to indicate the correct oxygen percentage within 0 1 as described earlier in this chapter Note After each adjustment wait for the reading to stabilize before performing any additional adjustments d Press CAL Switch S3 and hold for 5 seconds until the LED s stop blinking to EXIT programming mode 5 Stop the flow of calibration gas to the unit The FGA 311 In Situ Flue Gas Oxygen Transmitter is now properly calibrated and ready for use 40 FGA 311 User s Manual Chapter 4 Calibration 4 5 2 Calibrating with a PC Connection To calibrate the analyzer with a personal computer PC connected via the RS232 port complete the following steps Note See Operation and Programming on page 17 for general information on using the PC connection 1 Establish a flow of atmospheric air into the calibration port for at least five minutes at a flow rate of 1000 cc min 2 SCFH This air may be obtained by tapping a line off the reference air source See Figure 7 on page 16 for a suggested piping arrangement 2 Perform optional AIR calibration as follows b c d e Press ESC to move from run mode to the User Program Using the SPACE key if necessary make sure OPTS is highlighted and then press ENTER Use the SPACE key to select the AIR option and then press ENTER Wait for the read
56. e powering up the unit start the flow of reference air Be sure that the reference air source is connected to the correct port as shown in Figure 2 4 on page 2 9 The recommended reference air is instrument air 20 93 oxygen at a flow rate of 20 50 cc min Note The zirconium oxide oxygen sensor can not provide accurate readings without a known oxygen percentage on the reference side of the cell Allow the reference air to flow for at least five minutes prior to operation Power may now be applied to the unit Since the FGA 311 does not have its own power switch the main disconnect must be used to power the analyzer on Simply place this switch in the ON position and allow the analyzer to warm up for at least one hour three hours if possible before taking any readings Note For compliance with the European Union s Low Voltage Directive 73 23 EEC this unit requires an external power disconnect device such as a switch or circuit breaker The disconnect device must be marked as such clearly visible directly accessible and located within 1 8 m 6 ft of the unit The FGA 311 is designed to comply with the LVD Directive per the requirements of EN 61010 with the following exception The 230 VAC unit passes with a test voltage of 1 800 VAC Refer to Table D 10 of Annex D in EN 61010 The red fault light DS4 and one of the green oxygen range indicators DS1 DS2 or DS3 on the printed circuit board will blink until the FGA 311 has reached
57. e unit s mounting threads a calibration gas connection and a reference air connection In addition the enclosure houses the printed circuit board and provides two ports for electrical conduit or cable glands e All of the electrical components including the replaceable fuse are mounted on the printed circuit board PCB All electrical connections for the line power 4 20 mA recorder output and RS232 interface are made to the PCB e A probe assembly that extends into the flue gas stream e A heater sub assembly that maintains the oxygen sensor at the proper operating temperature for efficient operation e A zirconium oxide oxygen sensor to measure the percentage of oxygen in the flue gases e A filter assembly that protects the oxygen sensor from particulates in the flue gas stream The FGA 311 has been designed to permit troubleshooting maintenance and adjustment of the instrument without removing the unit from the flue FGA 311 User s Manual 1 Chapter 1 General Information 1 1 Introduction cont Standard Weatherproof Explosion Proof Flameproof Side Views Flame Arrestor FGA311 End Views
58. ear below that is if D had been pressed to clear any previous display of the table Use Offset Table YES NO Press SPACE to select YES and then press ENTER The offset table should appear at the bottom of the screen The offset table gives the user entered Duty Cycle values with their corresponding offset values Also the line above the table headers should read that the offset is enabled in addition to displaying the current duty cycle reading and the calculated offset value FGA 311 User s Manual 85 Appendix E Advanced Calibrations E 1 Duty Cycle Offset cont DC Ofst Entries 1 2 3 4 5 Select number 1 from the DC Offset Entries menu and press ENTER Use Entry 1 YES NO Select Yes for Use Entry 1 and press ENTER Choosing Yes activates a DC Offset entry and will be used for offset calculations The table entry for entry 1 should now show Enabled The offset reading above the table should now display a value other than zero Entry1 DC Offset To change the DC value select DC and press ENTER Entry 1 DC Offset To change the Offset value select Offset and press ENTER All entries 1 5 are edited in the same way Press ESC to return to run mode co oO FGA 311 User s Manual A AIR Calbranion doutes va pa macer eee o ew wes 25 B l i PAPA PA Ohne pnw Saad Rae as 9 C Cable Entry DEVICES 2 kak Rare tae VR RU LED GNG 79 Cable R8232
59. eatherproof Assembly Drawing 705 764_rev N Sheet 2 WPF SHOWN SIZE DRAWING NUMBER REV EM 9 4 96 CM 12 18 96 CHECKED 705 764 N SALES BF 12 18 96 CERT pe sns NONE DO NOT SCALE DWG SHEET 2 oF 3 2 1 FGA 311 User s Manual 74 Appendix B FGA 311 Drawings ron DMeS TON epoy SIZO VW NVHLIYM soisi3wvNva V 3 5 1334S INSIST IZZ L INI SIIALINYNVA Ll ISHON 61 45 REF 3 4 NPT 2 PLACES REF Figure 20 FGA 311 Explosion Proof Assembly Drawing 705 764 rev N Sheet 3 XPF SHOWN END VIEW DRAWN EUM 9 4 96 DRAWING NUMBER APP D CHECKED 705 764 BF 12 cert DO NOT SCALE DWG sHEET 3 oF 3 1 FGA 311 User s Manual 75 Appendix B FGA 311 Drawings NOTES KEE IF ILE 2z H RN HF E TB1 T TRI ER IPC AN LATEST REVISION HCLES FREE OF ARE NOT INSTALLE AL ATING 1 E ECIFICATION 714 RLL E TEST INT ALL LEAD N TT IDE T HOT NNECTI E L 1 E HHECTI HOT GLUE T 1 RN IN BETWEEN 3 PND IN BETWEEN IMENSIONS ARE IN INCHE 703 1216_rev J ing t Board Drawi ted Circui In FGA 311 Pr Figur
60. een engineered for long trouble free service some components may require occasional replacement The FGA 311 has been designed for quick and easy field replacement of these components when it does become necessary 6 2 Probe Tip Replacement The only field replaceable external component of the FGA 311 is the probe tip The probe tip may become clogged or cracked over time and require cleaning or replacement If this is the case refer to Figure 14 and complete the following steps 1 Power down the FGA 311 and allow approximately two hours for it to cool down to ambient temperature WARNING Disconnect the main power from the unit and allow at least two hours for the system to cool down before proceeding with the following steps Disconnect all electrical and mechanical lines from the analyzer 2 3 Remove the unit from the flue See Installation on page 7 for details on mounting the analyzer to the flue wall 4 Unthread the existing probe tip from the end of the probe base 5 Fither clean the existing probe tip or if it is damaged obtain a replacement IMPORTANT Do not use a thread sealant on the probe threads However a dry high temperature graphite based lubricant may be used 3 4 NPT Thread dom Base DES Probe Tip for 19 probe Figure 14 Probe Tip Replacement FGA 311 User s Manual 55 Chapter 6 Service and Maintenance 6 2 Probe Tip Repla
61. ements of electrical apparatus for category d The product is an electrical apparatus and must be installed in the hazardous area in accordance with the requirements of the EC Type Examination Certificate The installation must be carried out in accordance with all appropriate international national and local standard codes and practices and site regulations for flameproof apparatus and in accordance with the instructions contained in the manual Access to the circuitry must not be made during operation Only trained competent personnel may install operate and maintain the equipment The product has been designed so that the protection afforded will not be reduced due to the effects of corrosion of materials electrical conductivity impact strength aging resistance or the effects of temperature variations The product cannot be repaired by the user it must be replaced by an equivalent certified product Repairs should only be carried out by the manufacturer or by an approved repairer The product must not be subjected to mechanical or thermal stresses in excess of those permitted in the certification documentation and the instruction manual The product contains no exposed parts which produce surface temperature infrared electromagnetic ionizing or non electrical dangers The setting of the electronic protective device ensuring that the temperature class indicated in this certificate is fulfilled shall be affected for each apparatus
62. eps 1 Connect the RS232 serial port leads to TB2 as follows Note Before the FGA 311 may be programmed using its built in RS232 interface the serial port of the personal computer PC must be configured to the following specifications 9600 Baud 8 Data Bits 1 Stop Bit Non Parity Xon Xoff Flow Control Note The serial port connection should be made with a GE 704 668 cable assembly or its equivalent To assemble an equivalent cable refer to Figure 23 on page 78 of this manual a Connect the Ground lead the green wire from pin 5 of the DB9 connector on the PC to pin 1 b Connect the Receive lead the red wire from pin 2 of the DB9 connector on the PC to pin 2 c Connect the Transmit lead the white wire from pin 3 of the DB9 connector on the PC to pin 3 2 Connect the 4 20 mA analog output leads to TB2 as follows a Connect the 4 20 mA Return lead to pin 4 b Connect the 4 20 mA Signal lead to pin 5 Proceed to the next section for a description of the internal factory installed wiring 14 FGA 311 User s Manual Chapter 2 Installation 2 7 2 Factory Connections In addition to the user connections described above the following connections are made at the factory to terminal blocks J2 and J3 e Thermocouple connections to J2 on pins 1 and 2 Oxygen sensor connections to J2 on pins 3 and 4 Heater connections to J3 on pins 1 and 3 For reference purposes only these factory connec
63. etting before the 20 mA setting This will ensure optimum accuracy of the instrument Set Switch S1 5 Push CAL Switch S3 and hold for 5 seconds to access the TRIM O2 20mA option Adjust the value with ADJ Switch S2 until the output signal reads 20 mA Press Switch S3 and hold for 5 seconds to EXIT programming mode IMPORTANT After the programming has been completed reinstall the cover on the FGA 311 enclosure Do not operate the FGA 311 with the cover permanently removed N 2 FGA 311 User s Manual Chapter 3 Operation and Programming 3 9 Programming from a Computer Terminal In the following instructions the actual terminal screen display is shown in the left column while the required user response is shown in the right column Keyboard inputs are indicated by square brackets i e ESC means to press the escape key on the keyboard Also to change a displayed numeric value use the and keys to adjust the current value to the desired setting For reference the screen display of two typical menu lines is shown in Figure 9 The first line shown represents the menu line that appears on the terminal screen as soon as the User Program has been accessed The second line appears after ESC is pressed Note the location of the selection brackets which highlight the current menu choice ESC RUN20 93 0 700 C OPTS TRIM EXTRA Figure 9 Typical Menu Lines Navigating through the User Program is easy u
64. flange is oriented with its bolt holes straddling the vertical and horizontal center lines 2 Weld a mating flange onto the end of the pipe as shown in Figure 5 on page 11 Note Standard available factory options include 3 300 Ib ANSI 4 150 Ib ANSI and DN80 PN16 mounting flanges A separate mating flange can also be supplied with the unit FGA 311 User s Manual 9 Chapter 2 Installation 2 6 Mounting the Analyzer cont Before mounting the FGA 311 analyzer assembly onto the mating flange mark the enclosure in line with the probe holes Then complete the following steps IMPORTANT The probe holes must be positioned on the downstream side of the probe See Figure 5 on page 11 for the proper orientation 1 Slide the gasket over the probe assembly and up against the mounting flange on the analyzer Note Be sure to use a suitable high temperature gasket for this application 2 Orient the analyzer so the probe holes are properly positioned on the downstream side of the probe and slide the probe through the hole in the mounting wall until the two flanges meet 3 Secure the analyzer in place by fitting bolts into the matching flange mounting holes and fastening the bolts with nuts and washers Make sure that the gasket is properly positioned between the two flanges This completes the mounting of the FGA 311 The required external connections are discussed in the following sections 10 FGA 311 User s Manual Chapter 2 Ins
65. from the unit and allow at least two hours for the system to cool down before proceeding with the following steps 2 Remove the sensor heater sub assembly as described in Removing the Sensor Heater Sub Assembly on page 59 3 Pull the 3 wire connector off terminal block J3 and the 6 wire connector off terminal block J2 on the printed circuit board Remove the sensor heater cable assembly from the enclosure 4 Disconnect all ground leads from the two grounding lugs on the inside of the FGA 311 enclosure 5 Pull the 2 wire line power connector from terminal block TB1 on the PC board In a similar manner pull the 5 wire control signal connector from terminal block TB2 on the PC board 6 Using a 1 4 nut driver remove the two standoffs that secure the printed circuit board to the bottom of the enclosure 7 Carefully pull the printed circuit board out of the enclosure It will be necessary to angle the board slightly to work it past the two grounding lugs on the sides of the enclosure 6 6 2 Installing the Printed Circuit Board Refer to Figure 21 on page 76 for an illustration of the printed circuit board To install the new printed circuit board refer to Figure 16 on page 58 and completing the following steps 1 With the component side facing away from the enclosure insert the PC board into the enclosure Angle the board as required to get it past the two grounding lugs on the sides of the enclosure 2 Secure the printed ci
66. information regarding a specific problem The table will indicate the location of a more detailed discussion of the problem and its solution IMPORTANT This symbol indicates Caution risk of electric shock LN When working within the FGA 311 enclosure be aware that full line voltage is present at terminal block TB1 on the printed circuit board if the power is still applied to the unit Be sure to observe any warnings noted in the individual troubleshooting sections of this chapter Refer to Service and Maintenance on page 55 for the location or replacement of any components mentioned during the troubleshooting procedure Table 4 Troubleshooting Guide Problem Description Possible Cause s Go To Temperature Problems ER2 Warning Warming Up replaces RUN on the PC and the red fault LED flashes two times on the FGA 311 1 insufficient warm up time allowed page 47 2 defective heater or thermocouple 3 defective wiring or PC board 1 2 1 ER3 Open Thermocouple replaces RUN on the PC and the red fault LED flashes three times on the FGA 311 defective thermocouple page 48 defective wiring or PC board ER4 Heater Failure replaces RUN on the PC and the 1 defective heater page 49 red fault LED flashes four times on the FGA 311 2 defective wiring or PC board Output Problems no response from the FGA 311 4 20 mA RS232 and PC 1 no power to unit page 50 Board LEDs show no ou
67. ing to stabilize Press ENTER to accept the new offset value Press ESC to leave the User Program and return to run mode 3 Stopthe flow of atmospheric air to the calibration port and begin the flow of the chosen calibration gas Allow this flow to continue for at least five minutes at a flow rate of 1000 cc min 2 1 SCFH 4 Perform the GAS calibration as follows a b B g Note e f Press ESC to move from run mode to the User Program Using the SPACE key if necessary make sure OPTS is highlighted and then press ENTER Use the SPACE key to select the GAS option and then press ENTER Use the and keys to adjust the O2 value to correspond with the known oxygen content of the calibration gas After each adjustment wait for the reading to stabilize before performing any additional adjustments Press ENTER to accept the new oxygen value Press ESC to leave the User Program and return to run mode 5 Stop the flow of calibration gas to the unit The FGA 311 In Situ Flue Gas Oxygen Transmitter is now properly calibrated and ready for use FGA 311 User s Manual 41 Chapter 4 Calibration 4 6 Resume Operation If a temporary calibration gas connection was made disconnect the calibration gas line and reinstall the plug on the calibration gas port If a permanent calibration gas connection was installed close the shut off valve Then normal operation of the analyzer may be resumed 4
68. ion and Programming 3 9 4c Set Up Heater Control Although the default values for the P and I parameters of the FGA 311 PID heater control circuit are suitable for most applications it may sometimes be necessary to fine tune these parameters Refer to The Heater Control Circuit on page 5 for a discussion of the PID circuit If an adjustment is indicated proceed as follows IMPORTANT Always consult the factory before changing the P or I values COM ERR PID FRZ RESP OFST Press SPACE to select PID and then press ENTER Proceed to the appropriate section to set the desired parameter SET specify the temperature set point normally 700 C SET P O DEFAULT Make sure SET is highlighted and then press ENTER SET xxx Degrees C Enter the desired set point value and press ENTER Press ESC to return to run mode or proceed to the next section to continue programming the PID sub menu P set the proportional band value SET P O DEFAULT Press SPACE to select P and then press ENTER P xxx Degrees C Enter the desired proportional band value and press ENTER Press ESC to return to run mode or proceed to the next section to continue programming the PID sub menu FGA 311 User s Manual 31 Chapter 3 Operation and Programming 3 9 4c Set Up Heater Control cont I set the integration time value SET P I O DEFAULT Press SPACE to select I and then press ENT
69. ions for installing electrical equipment 22 Unpacking the Unit Remove the analyzer from its shipping container and make sure that all items on the packing slip have been received If anything is missing contact the factory immediately The analyzer as shown in Figure 4 is shipped fully assembled and ready to install CAUTION When unpacking the analyzer be careful not to damage the probe It is covered with a porous ceramic filter that will easily crack if it is knocked against a hard surface Enclosure 3 4 NPT PC Board Calibration Gas Inlet Probe 1 1 2 NPT Sanaa Heater N 3 4 NPT 26 114 Figure 4 The FGA 311 In Situ Flue Gas Analyzer FGA 311 User s Manual 7 Chapter 2 Installation 2 3 Line Power Requirements Each FGA 311 analyzer is factory configured for the proper line voltage as specified at the time of purchase The available options include the following e Japan 100 VAC e U S A 110 120 VAC e Europe 220 VAC Australia 240 VAC CAUTION Tochange the line voltage to the unit contact the factory for instructions DO NOT make sucha change without first obtaining proper instructions 2 4 Selecting the Site Environmental and installation factors should already have been discussed with a GE applications engineer or field sales person before the FGA 311 arrives The analyzer must be installed either in a furnace or boiler wall or in a flue duct Ideally the end of the p
70. le the exposed ends of the oxygen cell with bare fingers as deposits of skin oils and or salts may seriously impair sensor operation 2 Grasp the black plastic block at the end of the sensor heater sub assembly and screw the assembly into the threads at the base of the enclosure Proper tightening of the assembly requires that it be turned clockwise until it is hand tight and then turned an additional 1 4 turn 3 Attach the 6 wire connector to the end of the sensor heater sub assembly 4 Push the 1 8 black calibration gas hose onto the calibration gas fitting on the sensor heater sub assembly 5 Reinstall the cover on the enclosure as described in Cover Removal and Reinstallation on page 56 and power up the FGA 311 After the unit has heated up to its normal operating temperature of 700 C about thirty minutes data collection may be resumed 6 6 Printed Circuit Board Replacement If the printed circuit board becomes defective replace it by referring to Figure 16 on page 58 and completing the steps in the following sections 60 FGA 311 User s Manual Chapter 6 Service and Maintenance 6 6 1 Removing the Printed Circuit Board Remove the defective printed circuit board as follows 1 Power down the FGA 311 and allow at least two hours for the unit to cool down to ambient temperature Remove the cover from the enclosure as described in Cover Removal and Reinstallation on page 56 WARNING Disconnect the main power
71. low Shield Orientation coo 10 Freeze MOG ico ose haa b hawakan 33 53 85 Fuse RepIaCING ce sama e e E hes 57 G Gas Callbration i is bcc be RR dae 22 25 H Heater ROpISOID osse sobca e AA 59 TESNO 5 deg osa cupidis bati d dpud ts 47 NULL aciei rp aca d hae dy ou e ird ted 15 Heater Control o 2522 Ry ANA ET RAVESES Jl l Information Paragraphs a V Installation Fange MOUNENGS ssas Sepe Sexe LIGA AER ors 9 Site Selection seo s KAG sPerRESU PRRAMEEERaSS 8 Integration Time Value waa 3 32 K Keystrokes Computer Terminal 4a paaa x HRGK AS FG Jag 23 L LED S DSI DS5 2 sunu T TROUPE V RA RA 21 Line Power Available ODDS isan tee apa BIGA RES tues 8 LT ARR AREPRP ERE NAKAPA PEP ANO 12 LVD Directive 0 eee eee 12 18 79 87 Index M Menu MOD srece 91a dace mae ad Bee eat 19 N Nernst Equation s senaeta e enw KAW NAA 19 69 0 Offset Setting Lis soc I een ex YY ERU ees hes 85 OPTS MGI C m 24 Overheat Value saaan 32 85 Oxygen Range Setting 22 25 Oxygen Sensor Cali auus 503 43 oe a cea ena eee ANAN 40 DRAWING wa oen yere SD REX sew X See ees 3 OUIDUCVONGOE AA PAA PP 37 TESUNG PAA 52 Theory of Operation err rh DAA kA 3 WN ai PNP PAN PAG ATA PREHO 15 P PID Heater Control v2 63 isses kaaa 5 31 Plumbing A Typical System ocak oes paasa Rs 16 Calibration GaS vi s SndGhSaeeee eoesies 15 Reference Air cee cece ees 15 Probe Assem
72. oltage to the unit without first obtaining instructions from the factory WARNING Improper connection of the power line or connection to the wrong voltage may result in an electrical hazard Note For compliance with the European Union s Low Voltage Directive 73 23 EEC this unit requires an external power disconnect device such as a switch or circuit breaker The disconnect device must be marked as such clearly visible directly accessible and located within 1 8 m 6 ft of the unit The FGA 311 is designed to comply with the LVD Directive per the requirements of EN 61010 with the following exception The 230 VAC unit passes with a test voltage of 1 800 VAC Refer to Table D 10 of Annex D in EN 61010 Connect the line power to terminal block TB1 as shown in Figure 6 on page 13 by completing the following steps 1 Connect the LINE black lead to pin 1 on TB1 2 Connect the NEUTRAL white lead to pin 2 on TBI 3 Connect the GROUND green lead to the earth ground screw inside the enclosure Proceed to the next section to wire the control signals 12 FGA 311 User s Manual Chapter 2 Installation 2 7 Wiring the Analyzer cont Heater Connections TB1 Power Power Voltage Options J3 Terminal Block Terminal Block Factory Installed Description Pin Description Power Jumpers Fuse 1 Heater 1 Line 115V W1W3 W4W5 1 2A 2 No Connection 2 Neutral 230V W2 W6 1 4A 3 Heater
73. on 2 current mA 4 16e Pangan percentage 2 range setting For example if the calibration gas is 2 O and the O range is set to 5 the mA output should be 4 16 2 5 10 4 mA Figure 11 on page 39 shows a graphical representation of the procedure For the same example pick the applicable range curve R 5 Then move from the chosen oxygen percentage 2 0 on the horizontal axis up to the range curve and move across to the vertical axis to read the correct analog output 10 4 mA To monitor the analyzer s response to the calibration gas remove the wire from pin 4 or pin 5 on terminal block TB2 and install a digital ammeter between the removed wire and the pin The current should measure within 0 3 mA of the 5 O readings listed in Table 3 on page 37 Alternatively the oxygen sensor voltage output may be measured directly by connecting a digital voltmeter across pins 3 and 4 of terminal block J2 4 4 The Calibration Gas System The calibration gas should be introduced to the FGA 311 by a system similar to the one shown in Figure 7 on page 16 The calibration port plug that is supplied with the FGA 311 must be removed and a temporary connection made to calibrate the oxygen sensor However if a permanent connection is preferred it should be as short as possible and it should include an isolation valve next to the calibration gas port on the analyzer IMPORTANT The reference air supply to the FGA
74. our wrist Also avoid touching the pins on the EPROM with bare fingers as skin oils can prevent proper electrical contact with the socket 1 Align the notch on the EPROM with the notch on its socket and firmly press the EPROM into the socket on the printed circuit board until it is evenly and completely seated 2 Reinstall the PC board as described in Installing the Printed Circuit Board on page 61 3 Reinstall the cover on the enclosure as described in Cover Removal and Reinstallation on page 56 and power up the FGA 311 After the unit has heated up to its normal operating temperature of 700 C about thirty minutes data collection may be resumed FGA 311 User s Manual 63 Chapter 6 Service and Maintenance 6 8 Spare Parts List The components necessary to maintain and repair the FGA 311 are readily available from GE The descriptions and part numbers for the major components are listed in Table 5 Note To purchase replacement parts have the serial number of the unit available before contacting GE Part No 214 130 02 Table 5 Spare Parts List Description 2 Pin Terminal Block 422 011 01 Flame Arrestor Probe Tip 316L SS 422 011 02 Flame Arrestor Probe Tip Inconel 601 703 1216 04 Main PC Board 115 VAC with CJC 703 1216 05 Main PC Board 230 VAC with CJC 705 1028 02 Sensor Assembly Normal Temperature 115 VAC 705 1028 03 Sensor Assembly High Temperature 115 VAC
75. ous KAG 14 2 12 Factory CONNCCIIONS anakan otro Ex ck down Pb ss pK ERE Per LEYES RENE XR E QE X ERE RENE dex 15 2 8 Reference Air and Calibration Gas Lines 3 anakan eed REESE DRE R RUERE bob kREEPERbU RED E Ea rd dod 15 Chapter 3 Operation and Programming SA INTOOUCOON P URTUUULTTT 17 az Preventing Common Problems cusa oor KENANGAN xa OE YO E opis SER ERE RERERUA Sana EEEE ovd a et o ed 17 33 POWENNG UD cioe dake ciduth NIEL Plata d eia e oce UNEEL BER DERE E E Rd eR RT AUC Rp Rt p S ro 18 3 4 Taking Measurements sixteen tie ea EE ww X osa ww D ARKA Ba RAE hens E URL ale RR KR cR LG CR 19 5 Data REcords pee 19 SE CO ro X AE E E a r E E 19 34 Programming OPTIONS ciexsescser ceo xke pam Rx RE RR ERE EEEE E EE EEEE EEEN NEE 19 3 8 Programming with Manual SWIECIIBS Li s ice EE EE AA GA BpER dnbie Rab barril ios eaea facon 20 3 8 1 DescHplon or SwitcHes and LENG ics EBA KWAK AK ADIK Pott bride fd Rd duce 21 3 82 Manual Programming Instructions aaa nennen nnnm 22 39 Programming from a Computer Terminal csse mmm 23 3 9 1 RS232 Serial Port Settings ciigasueseletacidaadesiaedasiseelesinederineniause tiene KAME A WA NLA 24 ci wAe uii e mUrTT 24 39291 OISGECHIDFAEHOD 6 en ios nac o ex mph Det BOE Ex aote bala Ba aou e dd op pM pna 25 3 9 2b Gas Measurement CaliDraliai ies eos bush Ee E ER ERR eeEERRRRUHRDERO KE EE RE Re duh 25 3 9 20 Set OK Ge RANJE M r 25 39 3 TRI
76. ow all applicable local safety codes and regulations for installing electrical equipment 3 2 Preventing Common Problems Because of the extreme conditions in monitoring flue gases and the complexity of the FGA 311 measurement techniques some simple precautions should be taken with the instrument Failure to observe these basic procedures can lead to operational difficulties Compliance with the following instructions will help to eliminate such common problems Do not use pipe thread compounds on any part of the FGA 311 Many pipe thread compounds emit combustible vapors that may cause inaccurate readings Do not handle the sensor assembly any more than is absolutely necessary Although some scratches on the platinum electrode can be tolerated rubbing the coating should be avoided Also the transfer of skin oils to the electrode can cause erroneous readings e Scrubbing the sensor while washing it or washing a hot sensor can damage or destroy it Clean the sensor only by rinsing it with clean water after the sensor has cooled e Installing a cold probe assembly into a hot flue gas stream can cause damage to the filter and or sensor Always allow the probe assembly to gradually heat up to normal operating temperature before subjecting it to hot flue gases If any problems not covered in this manual are encountered contact GE for assistance FGA 311 User s Manual 17 Chapter 3 Operation and Programming 3 3 Powering Up Befor
77. r installing electrical equipment IMPORTANT This symbol indicates Caution risk of electric shock LN 4 2 Recommended Calibration Gas Calibration of the FGA 311 analyzer requires a calibration gas of precisely known composition The following calibration gas is recommended by GE e 5 096 O 95 0 Ng Note The calibration gas cylinder must be certified as to the exact composition of the gas A 5 0 Op calibration gas should produce an oxygen sensor voltage output of 30 0 1 5 mV at the usual sensor operating temperature of 700 C The corresponding 4 20 mA analog output will depend on the programmed oxygen range as shown in Table 3 Table 3 Calibration Gas Current Outputs Max 07 Om 200mA 200 ma Other calibration gases may be used as long as the oxygen content of the calibration gas is approximately equal to the oxygen percentage in the flue gases to be measured Of course the voltage output of the oxygen sensor and the corresponding 4 20 mA analog output would differ from those listed above Also the listed values will vary if the oxygen sensor temperature is different from the standard 700 C FGA 311 User s Manual 37 Chapter 4 Calibration 4 3 Measuring the Calibration Response Refer to The Nernst Equation on page 69 to calculate the expected oxygen sensor output voltage at whatever 05 and operating temperature are being used Calculate the corresponding 4 20 mA analog output signal using Equati
78. ramming the TRIM menu 26 FGA 311 User s Manual Chapter 3 Operation and Programming 3 9 4 EXTRA Menu Use the following procedure to move through the EXTRA menu RUN 20 939602 700 0C Press ESC to move from run mode to the User Program Note While in the EXTRA menu you may return to run mode at any time by pressing the ESC key OPTS TRIM EXTRA Press SPACE to select EXTRA and then press ENTER 394a Selecting Terminal Type COM ERR PID FRZ RESP OFST Make sure COM is selected and then press ENTER TTY ANSI Press SPACE to select the desired option and then press ENTER To return to the EXTRA menu press BACKSPACE Note Select TTY to interface the FGA 311 with a Teletype terminal or select ANSI to use a computer terminal that communicates via the standard ASCII character set For most modern personal computers select the ANSI option Press ESC to return to run mode or proceed to the next section to continue programming the EXTRA menu FGA 311 User s Manual 27 Chapter 3 Operation and Programming 394b Error Handling Set Up IMPORTANT Jt is recommended to consult the factory for assistance if you choose to use the error handling options COM ERR PID FRZ RESP OFST Press SPACE to select ERR and then press ENTER This sub menu permits set up of the responses of the FGA 311 to various error situations The following error states may be configured via this
79. rcuit board to the base of the enclosure by installing the two standoffs with a 1 4 nut driver IMPORTANT The printed circuit board can be installed in two different orientations that are rotated 180 from each other Orient the board so that the fuse is located near the power cable 3 Plug the power connector and the control signal connector into terminal block TB1 and terminal block TB2 on the printed circuit board respectively These connectors are polarized and can only be inserted into the terminal blocks in the proper orientation 4 Reconnect all ground leads to the two grounding lugs on the inside of the enclosure 5 Reinstall the sensor heater cable assembly by connecting the 3 wire connector to terminal block J3 and the 6 wire connector to terminal block J2 on the printed circuit board 6 Install the sensor heater sub assembly as described in Installing the Sensor Heater Sub Assembly on page 60 7 Reinstall the cover on the enclosure as described in Cover Removal and Reinstallation on page 56 and power up the FGA 311 After the unit has heated up to its normal operating temperature of 700 C about thirty minutes data collection may be resumed FGA 311 User s Manual 61 Chapter 6 Service and Maintenance 6 7 EPROM Replacement To permit software upgrades and to allow replacement of a damaged EPROM the EPROM chip U3 has been socketed on the solder side of the printed circuit board Refer to Figu
80. re 17 and complete the following steps to replace the EPROM 9 Ris C18 R14 E C36 O R24 R25 o 5 C20 RIG R9 R19 C32 R20 R18 633 s 2 8 8 5 Q Figure 17 Solder Side of PC Board 1 Power down the FGA 311 and allow at least two hours for the unit to cool down to ambient temperature Remove the cover from the enclosure as described in Cover Removal and Reinstallation on page 56 WARNING Disconnect the main power from the unit and allow at least two hours for the system to cool down before proceeding with the following steps 2 Remove the printed circuit board as described in Removing the Printed Circuit Board on page 61 3 Turn the printed circuit board over to the solder side and locate the socketed EPROM U3 Using the end of a paper clip or similar object carefully pry the EPROM U3 out of its socket Pry the chip out evenly by lifting it a little at a time at each of the four corners in sequence 62 FGA 311 User s Manual Chapter 6 Service and Maintenance 6 7 EPROM Replacement cont Remove the new EPROM from its anti static packaging and install it by completing the following steps CAUTION The EPROM is easily damaged by static electricity Before handling the chip touch an earth ground to discharge any static electricity and install a grounding strap on y
81. robe assembly should extend approximately 1 ft 30 5 cm into the flue gas stream Also the analyzer should be positioned so that the probe holes are on the downstream side of the probe see Figure 5 on page 11 e For furnaces locate the analyzer close to the combustion zone typically within the radiant section and always before the convection section Make sure that the probe s maximum operating temperature is not exceeded and that the probe is not situated in a non homogeneous flue gas mixture IMPORTANT f the ambient temperature in the vicinity of the probe can exceed 650 C 1202 F a high temperature probe assembly is required For boilers locate the analyzer downstream of the heat exchanger and just before the economizer air heater if one is installed The analyzer should not be placed downstream of any air heater because of possible air leaks that can cause inaccurate readings In general the sample point should be an area of high turbulence which will ensure a good homogeneous mixture of the flue gases Conditions to be avoided would include air leaks upstream of the sample point and dead spaces in the vicinity of the sample point 8 FGA 311 User s Manual Chapter 2 Installation 2 5 Bench Testing The analyzer was not designed to be calibrated outside the flue If you decide to operate it outside the flue please note It will take at least two hours to give reasonable numbers for verification Many time
82. s ESC to move from run mode to the main menu Note While in the OPTS menu you may return to run mode at any time by pressing the ESC key OPTS TRIM EXTRA Make sure OPTS is highlighted and then press ENTER Press ESC to return to run mode or proceed to the next section to continue programming the OPTS menu 24 FGA 311 User s Manual Chapter 3 Operation and Programming 3 9 2a Air Offset Calibration TST AIR GAS RNG Press SPACE to select AIR and then press ENTER AIR 20 939602 xxx xC Press ENTER to accept the new offset value and BACKSPACE to return to the OPTS menu To abort just press BACKSPACE to return to the OPTS menu Note Refer to Calibration on page 37 for a detailed description of the calibration procedures Press ESC to return to run mode or proceed to the next section to continue programming the OPTS menu 3 9 2b Gas Measurement Calibration TST AIR GAS RNG Press SPACE to select GAS and then press ENTER GAS x xx O2 xxx xC Adjust the O2 value with the and keys Press ENTER to accept the new value and BACKSPACE to return to the OPTS menu To abort just press BACKSPACE to return to the OPTS menu Press ESC to return to run mode or proceed to the next section to continue programming the OPTS menu 3 9 2c Set Oxygen Range TST AIR GAS RNG Press SPACE to select RNG and then press ENTER 02 R
83. s you will get a heater open message due to the fact that the unit has not reached the operating temperature in the allotted time Power down and then power up again e Any change in calibration will result in re calibration once the analyzer is installed in the flue 2 6 Mounting the Analyzer The FGA 311 has integral male 1 1 2 NPT mounting threads This permits a flange to be threaded onto the analyzer and the resulting assembly is then bolted to a mating flange on the furnace boiler wall or flue duct Note For installations where the FGA 311 may be exposed to water or other fluids install the unit with the breather see Figure 5 on page 11 facing downward Do not use any thread sealant during the installation Upon heating Teflon tape will melt and other sealants may emit gases that interfere with the oxygen readings Carefully follow the steps below to mount the FGA 311 In Situ Flue Gas Oxygen Transmitter The unit may be mounted in either a horizontal or vertical orientation IMPORTANT Direct mounting of the FGA 311 into a threaded hole using its mounting threads is not recommended Always use a mounting flange To prepare the installation site for mounting the analyzer complete the following preliminary steps 1 Fasten a short section of pipe having at least a 2 inside diameter into the process wall IMPORTANT Make sure that the pipe is long enough to permit installation of the flange mounting hardware and that the
84. se Shannon Free Zone East Shannon County Clare Ireland Tel 353 0 61 470291 E mail gesensingsnnservices ge com An ISO 9001 2008 Certified Company www ge mcs com en about us quality html www ge mcs com 2012 General Electric Company All rights reserved Technical content subject to change without notice 910 160 Rev E
85. sing the keystrokes in Table 2 and the instructions in the following sections Table 2 Computer Terminal Keyboard Entries Desired Action Keyboard Entry Move from run mode to programming mode ESC Move from programming mode to run mode ESC Move selection brackets SPACE Enter numerical data H Confirm selection or entry ENTER Start entry over again BACKSPACE Move up one level in program BACKSPACE Note The use of any keys on the keyboard other than those listed in Table 2 will not be recognized by the FGA 311 Any such keyboard entries will simply be ignored by the analyzer Also is a shifted key and the SHIFT key must be held while striking it FGA 311 User s Manual 23 Chapter 3 Operation and Programming 3 9 1 RS232 Serial Port Settings Before the FGA 311 may be programmed via its built in RS232 interface the serial port of the personal computer PC must be configured to the following specifications e 9600 Baud e 8 Data Bits e I Stop Bit No Parity e Xon Xoff Flow Control Note Jf the RS232 connection still does not work try reversing the leads on pins 2 and 3 of terminal block TB2 Refer to the computer s documentation for the correct procedures to configure and access the serial port Then proceed to the next section to begin programming the analyzer 3 9 2 OPTS Menu Use the following procedure to move through the OPTS menu RUN 20 93 O2 700 0C Pres
86. t to normal operation or replacing the instrument at the sole discretion of GE Sensing Fuses and batteries are specifically excluded from any liability This warranty is effective from the date of delivery to the original purchaser If GE Sensing determines that the equipment was defective the warranty period is one year from delivery for electronic or mechanical failures one year from delivery for sensor shelf life If GE Sensing determines that the equipment was damaged by misuse improper installation the use of unauthorized replacement parts or operating conditions outside the guidelines specified by GE Sensing the repairs are not covered under this warranty The warranties set forth herein are exclusive and are in lieu of all other warranties whether statutory express or implied including warranties or merchantability and fitness for a particular purpose and warranties arising from course of dealing or usage or trade Return Policy If a GE Sensing instrument malfunctions within the warranty period the following procedure must be completed 1 Notify GE Sensing giving full details of the problem and provide the model number and serial number of the instrument If the nature of the problem indicates the need for factory service GE Sensing will issue a RETURN AUTHORIZATION NUMBER RAN and shipping instructions for the return of the instrument to a service center will be provided 2 If GE Sensing instructs you to send yo
87. tage on reference face with respect to the flue gas face FGA 311 User s Manual 69 Appendix A The Nernst Equation A 3 TheFGA 311 The Nernst Equation specifically applicable to the FGA 311 analyzer is obtained by substituting the parameter values in the previous section into the general equation converting the natural logarithm base e to the common logarithm base 10 and converting the units for E45 to millivolts This results in Equation 4 E mV 0 049605 e T e log 4 P2 The FGA 311 measures the temperature at the sensor and automatically inserts the correct value into the Nernst Equation For example at the usual operating sensor temperature of 700 C Equation 5 is used E mV 48274 e log 2225 5 P2 The voltage drop across the zirconium oxide sensor as calculated from the Equation 5 is then sent to the linearizer circuit This circuit produces a linear 4 20 mA output that represents the percentage of oxygen in the flue gas and this signal is available to the user at pins 4 5 of terminal block TB2 on the printed circuit board 70 FGA 311 User s Manual Appendix B FGA 311 Drawings AppendixB FGA 311 Drawings For reference the following drawings are included in this appendix e Figure 18 FGA 311 Weatherproof Assembly Drawing 705 764 rev N Sheet 1 73 e Figure 19 FGA 311 Weatherproof Assembly Drawing 705 764 rev N Sheet 2 74 e Figure 20 FGA 31
88. tallation 2 6 Mounting the Analyzer cont e qeo joquo9 soDue J ing a M pai PO WF AR Boum pug 8 qe 9JeMpJeH iayeosg FG311 IN SITU ANALYZER Flange Mounting the FGA 311 q E ma 9ur JV dooog 1ndu aga Wg g UG w Jeysec 82U819 9Y D mum p eur Sec uoneJqie2 em Bununoy Nd pue d siqeD 9 qe2 JemMod Figure 5 T FGA 311 User s Manual Chapter 2 Installation 2 7 Wiring the Analyzer Connect the power and control signal wiring as described below and as shown in Figure 6 on page 13 which shows the printed circuit board mounted within the open FGA 311 enclosure The necessary connectors are supplied with the unit and they are plugged into the mating connectors on the printed circuit board prior to shipment CAUTION DO NOT power up the unit until instructed to do so CAUTION To meet CE Mark requirements all electrical cables must be installed as described in CE Mark and Regulatory Compliance on page 79 2 7 1 Wiring the Line Power Use one of the 3 4 NPT connections on the enclosure for installation of the power cable gland or conduit The FGA 311 has been preset at the factory for the line voltage specified at the time of purchase Never connect a different line v
89. tions are shown in Figure 6 on page 13 2 8 Reference Air and Calibration Gas Lines During normal operation the FGA 311 requires a constant supply of a reference air for the zirconium oxide oxygen sensor The recommended gas for this purpose is instrument air containing 20 93 oxygen at a flow rate of 20 50 cc min Connect this gas supply with 1 4 tubing and a valve to control the flow to the 1 4 compression fitting provided Refer to Figure 7 on page 16 for the location of this connector Also a separate gas supply is required for calibration of the instrument This line should be connected with 1 4 tubing and a valve to control the flow to the remaining 1 4 compression fitting on the FGA 311 See Figure 7 on page 16 for the location of this connector Note The calibration gas port must remain capped if no permanent plumbing is attached See Calibration on page 37 for a discussion of the recommended calibration gases and procedures In addition to the basic reference air and calibration gas lines a variety of ancillary equipment is recommended A typical system that will ensure efficient and reliable operation of the FGA 311 is illustrated in Figure 7 on page 16 FGA 311 User s Manual 15 Chapter 2 Installation 2 8 Reference Air and Calibration Gas Lines cont Flowmeter Calibration Gas Inlet Gauge
90. to calculate the oxygen content of the flue gas When a Yttrium doped zirconium oxide ceramic is heated to a temperature above 650 C it becomes an electrolytic conductor as vacancies in the crystal lattice permit oxygen ions to diffuse into the ceramic If there are different oxygen partial pressures on the two sides of the ceramic cell oxygen ions will migrate along the resulting concentration gradient This constitutes a transfer of electrons from one face of the ceramic to the other If the transferred charge is allowed to accumulate it gives rise to a potential gradient acting in the opposite direction thus tending to oppose further diffusion A 2 Equilibrium Conditions Under equilibrium conditions the potential gradient exactly balances the concentration gradient Porous coatings of a platinum catalyst on both surfaces of the ceramic cell serve as electrodes while still allowing the oxygen molecules to penetrate the coating and diffuse into the ceramic The measured voltage drop across the cell can be directly related to the ratio of the two oxygen partial pressures by means of Equation 3 the Nernst Equation RT P1 where F the Faraday 96 484 56 coulombs T absolute temperature K R gas constant 8 31441 volt coulomb mole K n electrons transferred per molecule 4 mole In natural logarithm 2 303 logio P O partial pressure on reference gas side 0 2093 P2 O partial pressure on flue gas side E vol
91. tput 2 blown fuse 3 defective PC board no RS232 output but the PC board LEDs and the 4 20 mA 1 defective wiring page 51 output are active 2 defective EPROM Oxygen Reading Problems ER1 Sensor Failure replaces RUN on the PC and the 1 defective oxygen sensor page 52 red fault LED glows constantly on the FGA 311 2 wiring problem 3 defective PC board percent oxygen always reads 20 93 1 air leak in plumbing page 53 2 defective wiring or PC board percent oxygen is stuck on same reading for more than 1 display left in FREEZE mode page 53 15 minutes 2 clogged filter oxygen reading is lower than expected 1 combustibles in sample gas page 54 oxygen reading is higher than expected 1 leak in plumbing page 54 44 FGA 311 User s Manual Chapter 5 Troubleshooting 5 3 Diagnostics Page One of the most important troubleshooting tools is the diagnostics page see Figure 12 It will show not only the error messages but also several parameters that will enable the factory representative to evaluate the performance of the analyzer in situ RUN 26 93 7402 706 0C CIC mV 1 43 CIC T 35 5 TC mV 22 71 raw TC 665 9 comp TC 700 0 Raw 02 mV 2 11 02 mV 6 60 inst 024 20 930 Sum 02 627 88 Ei 0 3491 Ep 6 6661 DC 0 3255 FP e Air Offset mV 2 11 Cos Offset 0 48 DUTY CYCLE OFFSET TABLE DISABLED Figure 12 Diagnostics Page for a Normal FGA 311 FGA 311 User s Manual 45 Chapter 5
92. under the responsibility of the manufacturer Furthermore this setting shall not be modified CE amp no content intended for this page GE DECLARATION Sensing OF CONFORMITY DOC 0035 Rev A We GE Sensing 1100 Technology Park Drive Billerica MA 01821 USA declare under our sole responsibility that the FGA300H and FGA300HX Horizontal Flue Gas Analyzers FGA300V and FGA300VX Vertical Flue Gas Analyzers FGA300D Display Unit FGA311 In Situ Flue Gas Oxygen Analyzer to which this declaration relates are in conformity with the following standards EN 61326 1 2006 Class A Table 2 Industrial Locations EN 61326 2 3 2006 EN 61010 1 2001 Overvoltage Category Il Pollution Degree 2 following the provisions of the 2004 108 EC EMC and 2006 95 EC Low Voltage Directives The units listed above and any ancillary equipment supplied with them do not bear CE marking for the Pressure Equipment Directive as they are supplied in accordance with Article 3 Section 3 sound engineering practices and codes of good workmanship of the Pressure Equipment Directive 97 23 EC for DN 25 A 4 LA nut Billerica August 2010 A Issued Mr Gary Kozinski Certification amp Standards Lead Engineer CE TUV Customer Support Centers U S A The Boston Center 1100 Technology Park Drive Billerica MA 01821 U S A Tel 800 833 9438 toll free 978 437 1000 E mail sensing ge com Ireland Sensing Hou
93. ur instrument to a service center it must be shipped prepaid to the authorized repair station indicated in the shipping instructions 3 Upon receipt GE Sensing will evaluate the instrument to determine the cause of the malfunction Then one of the following courses of action will then be taken e If the damage is covered under the terms of the warranty the instrument will be repaired at no cost to the owner and returned e If GE Sensing determines that the damage is not covered under the terms of the warranty or if the warranty has expired an estimate for the cost of the repairs at standard rates will be provided Upon receipt of the owner s approval to proceed the instrument will be repaired and returned FGA 311 User s Manual 91 Warranty no content intended for this page 92 FGA 311 User s Manual GE Sensing COMPLIANCE ATEX We GE Sensing 1100 Technology Park Drive Billerica MA 01821 USA as the manufacturer declare under our sole responsibility that the FGA 311 In Situ Flue Gas Oxygen Transmitter to which this declaration relates in accordance with the provisions of ATEX Directive 94 9 EC Annex II meets the following specifications C Cpe k 1180 ISSeP02ATEX028X T95 C IP66 Housing Furthermore the following additional requirements and specifications apply to the product e Having been designed in accordance with EN 50014 EN 50018 and EN 50281 the product meets the fault tolerance requir
94. ure on the natural resources we encourage you to use the appropriate take back systems Those systems will reuse or recycle most of the materials of your end life equipment in a sound way The crossed out wheeled bin symbol invites you to use those systems If you need more information on the collection reuse and recycling systems please contact your local or regional waste administration Visit http www ge mcs com en about us environmental health and safety 1741 weee reg html for take back instructions and more information about this initiative vi FGA 311 User s Manual Chapter 1 General Information Chapter 1 General Information 1 1 Introduction The FGA 311 In Situ Flue Gas Oxygen Transmitter monitors the combustion efficiency of a boiler or furnace by measuring the percentage of oxygen in the flue gases This self contained instrument is installed so that its zirconium oxide oxygen sensor is located directly in the stream of the flue gases The measurements may be recorded via the built in 4 20 mA output or transmitted to a computer terminal via the built in RS232 interface The FGA 311 is available with either the standard weatherproof enclosure or the optional explosion proof enclosure as shown in Figure 1 on page 2 However the operation and the internal components are the same for both configurations The FGA 311 consists of the following sub assemblies e An aluminum enclosure which includes a breather port th

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